Pruksawan, S., Chong, Y. T., Zhao, Y., Sivaraja, V. K., Ngo, A. C. Y., Jin, P., & Wang, F. (2024). Minimizing Polymer Curl Distortion and Heat Impact to Improve Digital Light Processing Printing Accuracy via Subdivision Method. Advanced Engineering Materials, 26(24). Portico. https://doi.org/10.1002/adem.202401674
Abstract:
Curl distortion has been a persistent challenge for vat photopolymerization‐based printing technology such as digital light processing (DLP), leading to structural deformation and print failures. This study presents a new approach to mitigate curling distortion and heat effects during DLP printing by dividing the printing layer image into sequential subimages, using a breadth‐first search algorithm. The progressive curing process, resembling a ripple pattern, results in a significant improvement in printing accuracy. The deviation is reduced tenfold when the layer image is divided into subimages with 10 pixels for a 32 mm diameter disc. Additionally, subdivision strategy helps to reduce the heat effect during photopolymerization, as monitored in situ by a long‐wave infrared camera. The successful reduction of residual stress using the subdivision strategy results in a 75% improvement in the mechanical performance of the printed products. The simple adoption of subdivision strategy in practical 3D printing applications is also demonstrated. For solid 3D printing structures, introducing intervals within the solid printing layers—such as using a grid structure instead of a fully solid one, can help to reduce curling and heat effects, thereby improving 3D printing accuracy.
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Publisher Copyright
Funding Info:
This research / project is supported by the A*STAR - RIE2025 Manufacturing, Trade and Connectivity (MTC) Programmatic Fund
Grant Reference no. : M24N3b0028
This research is supported by core funding from: SERC Central Research Fund
Grant Reference no. : TIMR211001bSERCRF
Description:
This is the peer reviewed version of the following article: Pruksawan, S., Chong, Y. T., Zhao, Y., Sivaraja, V. K., Ngo, A. C. Y., Jin, P., & Wang, F. (2024). Minimizing Polymer Curl Distortion and Heat Impact to Improve Digital Light Processing Printing Accuracy via Subdivision Method. Advanced Engineering Materials, 26(24). Portico
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