LLNL patents projection micro-stereolithography 3D printer
In October of this year, we reported a new method of 3D printing , large-area projection micro-stereolithography (LAPμSL), invented by Bryan Moran, an engineer at Lawrence Livermore National Laboratory (LLNL) in the United States. This method can use UV light to create larger, finer 3D objects than previously common micro-stereolithography. To this end, Moran also won the 2015 Federal Laboratories Alliance (FLC) West Region Award. Recently, Moran once again won the prestigious R&D 100 award for this technology. This award was awarded by R&D magazine and is known as the Academy Award for Science and Technology. In addition, Moran applied for a patent for a 3D printer based on the technology and announced some technical improvements to the upcoming second version.
In the scientific world, some discoveries are accidents, while others rely on inspiration. For Bryan Moran, his breakthrough discovery in 3D printing is due to purely aniration. "The trouble is the mother of invention. People worry that they can't make a larger object (using projection micro-stereolithography) while maintaining fineness," he said. “I did research and figure out how to implement it through calculations.â€
Projection micro-stereolithography is a 3D printing technology specially designed for micro-manufacturing. This technology mainly focuses a beam of light with a specific preset pattern onto the surface of a liquid resin that can be cured by ultraviolet light. The resin is then hardened layer by layer until a solid 3D object is formed. The process can create layer thicknesses on the order of 400 nanometers, but it is not ideal for applications that exceed microscale objects.
To solve this problem, Moran has combined a direct light processing technology with outstanding detail with a higher speed and a much larger area scanning method to develop a new method that enables researchers to print larger and more faster 3D. For complex objects while maintaining incredible high resolution.
Specifically, the LAPμSL 3D printer does not use a static exposure of millions of micromirrors, but uses specialized software developed by the LLNL team to scan, replicate and overlay high-resolution images over a large area. As a result, the 3D printer invented by Moran can print objects up to 10 cm in size, and its detailed features can reach the micron level.
“It combines a projector with a fine image scan to easily cover a much larger area with the same level of detail. It has the advantage of being much faster.†Moran said: “This is a leap. Because it combines two existing technologies in a unique way. It can create something you can't think of."
Moran began researching in the field of additive manufacturing three years ago. Prior to this, his research direction was in the field of laser and optics. Now he has patented the 3D printer he invented and has begun to improve on several aspects.
Moran has said that he is nearing an upgrade, and the upgrade will increase the work area by 10 times, speed by 10 times, and fineness by 5 times. In addition, the second version will feature a custom optics system and a larger scanning mirror, allowing the operator to 3D print complex objects of table size.
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