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research-article

Multi-Scale Stereolithography Using Shaped Beams

[+] Author and Article Information
Yong Chen

3715 McClintock Avenue, GER240 Los Angeles, CA 90089
yongchen@usc.edu

Huachao Mao

2676 Ellendale Place Los Angeles, CA 90007
huachaom@usc.edu

Yuen-Shan Leung

3715 McClintock Ave, GER240 Los Angeles, CA 90089
yuenshal@usc.edu

Yuanrui Li

3740 McClintock Ave Los Angeles, CA 90089
yuanruil@usc.edu

Pan Hu

3740 McClintock Ave Los Angeles, CA 90089
panhu@usc.edu

Wei Wu

3740 McClintock Ave Los Angeles, CA 90089
wu.w@usc.edu

1Corresponding author.

ASME doi:10.1115/1.4037832 History: Received June 13, 2017; Revised August 28, 2017

Abstract

Current Stereolithography (SL) can fabricate three-dimensional (3D) objects in a single scale level, e.g. printing macro-scale or micro-scale objects. However, it is difficult for the SL printers to fabricate a 3D macro-scale object with micro-scale features. In the paper a novel SL-based multi-scale fabrication method is presented to address such a problem. The developed SL process can fabricate multi-scale features by dynamically changing the shape and size of a laser beam. Different shaped beams are realized by switching apertures with different micro-patterns. The laser beam without using micro-patterns is used to fabricate macro-scale features, while the shaped laser beams based on small apertures are used to fabricate micro-patterned features. Accordingly, a tool path planning method for the multi-scale fabrication process is presented to build macro-scale and micro-scale features using different layer thicknesses, laser exposure time, and scanning paths. Compared with the conventional SL process using a fixed laser beam size, our process can manufacture multi-scale features in a 3D object with fast fabrication speed and good surface quality.

Copyright (c) 2017 by ASME
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