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Research Papers

A Fast Mask Projection Stereolithography Process for Fabricating Digital Models in Minutes

[+] Author and Article Information
Yayue Pan, Chi Zhou

 Daniel J. Epstein Department of Industrial and Systems Engineering, University of Southern California, Los Angeles, CA 90089

Yong Chen1

 Daniel J. Epstein Department of Industrial and Systems Engineering, University of Southern California, Los Angeles, CA 90089yongchen@usc.edu

1

Corresponding author.

J. Manuf. Sci. Eng 134(5), 051011 (Sep 10, 2012) (9 pages) doi:10.1115/1.4007465 History: Received December 09, 2011; Revised August 10, 2012; Published September 10, 2012; Online September 10, 2012

The purpose of this paper is to present a direct digital manufacturing (DDM) process that is an order of magnitude faster than other DDM processes that are currently available. The developed process is based on a mask-image-projection-based stereolithography (MIP-SL) process, in which a digital micromirror device (DMD) controls projection light to selectively cure liquid photopolymer resin. In order to achieve high-speed fabrication, we investigate the bottom-up projection system in the MIP-SL process. A two-way linear motion approach has been developed for the quick spreading of liquid resin into uniform thin layers. The system design and related settings for achieving a fabrication speed of a few seconds per layer are presented. Additionally, the hardware, software, and material setups for fabricating three-dimensional (3D) digital models are presented. Experimental studies using the developed testbed have been performed to verify the effectiveness and efficiency of the presented fast MIP-SL process. The test results illustrate that the newly developed process can build a moderately sized part within minutes instead of hours that are typically required.

Copyright © 2012 by American Society of Mechanical Engineers
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References

Figures

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Figure 2

An illustration of the bottom-up projection system

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Figure 3

Experimental setup for studying part separation forces in the MIP-SL process

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Figure 4

Pulling-up forces of a cured layer from a PDMS film in different settings: (a) T = 1 s, area = 625 mm2 ; (b) T = 0.5 s, area = 625 mm2 ; and (c) T = 1 s, area = 156 mm2

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Figure 5

The MIP-SL process based on the two-way movement design with PDMS

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Figure 6

Pulling-up forces of a cured layer based on the two-way movement design in different settings: (a) T = 1 s, area = 625 mm2 and (b) T = 1 s, area = 156 mm2

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Figure 7

Shearing force verification test

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Figure 8

The movement time in the X and Z axes in our prototyping system

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Figure 9

The building time of a layer in the two-way movement based MIP-SL process

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Figure 10

The prototype hardware system for the fast MIP-SL process

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Figure 11

Flow chart of the fast MIP-SL system and related software system

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Figure 13

A test of a head: (a) CAD model and (b)–(c) two views of the built object

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Figure 14

A test of a statue: (a) CAD model and (b)–(e) two views of the built objects in two liquid resins

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Figure 18

Layer building time of the test cases

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Figure 1

An illustration of the MIP-SL process

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Figure 16

A test of a hearing aide shell: (a) CAD model and (b)–(c) two views of the built object

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Figure 17

A test of a brush: (a) CAD model and (b) built object

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Figure 12

A test of a gear: (a) CAD model and (b) built objects in two liquid resins

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Figure 15

A test of teeth: (a) CAD model and (b)–(c) built objects in two liquid resins

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