Development of a 3D printer using scanning projection stereolithography

We have developed a system for the rapid fabrication of low cost 3D devices and systems in the laboratory with micro-scale features yet cm-scale objects. Our system is inspired by maskless lithography, where a digital micromirror device (DMD) is used to project patterns with resolution up to 10 µm onto a layer of photoresist. Large area objects can be fabricated by stitching projected images over a 5cm2 area. The addition of a z-stage allows multiple layers to be stacked to create 3D objects, removing the need for any developing or etching steps but at the same time leading to true 3D devices which are robust, configurable and scalable. We demonstrate the applications of the system by printing a range of micro-scale objects as well as a fully functioning microfluidic droplet device and test its integrity by pumping dye through the channels

Recent advances in 3D printing of biomaterials.

3D Printing promises to produce complex biomedical devices according to computer design using patient-specific anatomical data. Since its initial use as pre-surgical visualization models and tooling molds, 3D Printing has slowly evolved to create one-of-a-kind devices, implants, scaffolds for tissue engineering, diagnostic platforms, and drug delivery systems. Fueled by the recent explosion in public interest and access to affordable printers, there is renewed interest to combine stem cells with custom 3D scaffolds for personalized regenerative medicine. Before 3D Printing can be used routinely for the regeneration of complex tissues (e.g. bone, cartilage, muscles, vessels, nerves in the craniomaxillofacial complex), and complex organs with intricate 3D microarchitecture (e.g. liver, lymphoid organs), several technological limitations must be addressed. In this review, the major materials and technology advances within the last five years for each of the common 3D Printing technologies (Three Dimensional Printing, Fused Deposition Modeling, Selective Laser Sintering, Stereolithography, and 3D Plotting/Direct-Write/Bioprinting) are described. Examples are highlighted to illustrate progress of each technology in tissue engineering, and key limitations are identified to motivate future research and advance this fascinating field of advanced manufacturing

Compensation Zone Approach to Avoid Z Errors in Mask Projection Stereolithography Builds

Print-through results in unwanted polymerization occurring beneath a part cured using Mask Projection Stereolithography (MPSLA) and thus creates error in its Z dimension. In this paper, the "Compensation zone approach" is proposed to avoid this error. This approach entails modifying the geometry of the part to be cured. A volume (Compensation zone) is subtracted from underneath the CAD model in order to compensate for the increase in the Z dimension that would occur due to Print-through. Three process variables have been identified: Thickness of Compensation zone, Thickness of every layer and Exposure distribution across every image used to cure a layer. Analytical relations have been formulated between these process variables in order to obtain dimensionally accurate parts. The Compensation zone approach is demonstrated on an example problem.Mechanical Engineerin

Quantifying Dimensional Accuracy of a Mask Projection Micro Stereolithography System

Mask Projection Microstereolithography is capable for fabricating true three-dimensional microparts and hence, holds promise as a potential micro-fabrication process for micro-machine components. In this paper, the Mask Projection Micro-Stereolithography (MPµSLA) system developed at the Rapid Prototyping and Manufacturing Institute at Georgia Institute of Technology is presented. The dimensional accuracy of the system is improved by reducing its process planning errors. To this effect, the MPµSLA process is mathematically modeled. In this paper, the irradiance received by the resin surface is modeled as a function of the imaging system parameters and the pattern displayed on the dynamic mask. The resin used in the system is characterized to experimentally determine its working curve. This work enables us to compute the dimensions of a single layer cured using our system. The analytical model is validated by curing test layers on the system. The model computes layer dimensions within 5% error.Mechanical Engineerin

On the Use of Angled, Dynamic Laser Beams to Improve Stereolithography Surface Finish

Improved surface finish of Stereolithography (SLA) parts is an important goal for furthering the resolution of the technology. In order to improve the surface finish, a dynamic laser beam with changing angle, beam size, beam shape, and irradiance distribution is proposed. In this paper, an analytical irradiance model of an angled, dynamic laser beam in the SLA process is presented. This model is used to simulate cured shapes of SLA builds. Simulated build shapes are compared to established SLA analytical models and conclusions are drawn on the accuracy of the developed model.Mechanical Engineerin

Nanotailoring Stereolithography Resins for Unique Applications using Carbon Nanotubes

Nanostructured materials and exploiting their properties in stereolithography (SL) may open new markets for unique rapidly manufactured functional devices. Controlled amounts of multiwalled carbon nanotubes (MWCNTs) were successfully dispersed in SL epoxy-based resins and complex three-dimensional (3D) parts were successfully fabricated by means of a multi-material SL setup. The effect of the nanosized filler was evaluated using mechanical testing. Small dispersions of MWCNTs resulted in significant effects on the physical properties of the polymerized resin. A MWCNT concentration of .05 wt% (w/v) in DSM Somos® WaterShed™ 11120 resin increased the ultimate tensile stress and fracture stress an average of 17% and 37%, respectively. Electron microscopy was used to examine the morphology of the nanocomposite and results showed affinity between the MWCNTs and SL resin and identified buckled nanotubes that illustrated strong interfacial bonding. These improved physical properties may provide opportunities for using nanocomposite SL resins in end-use applications. Varying types and concentrations of nanomaterials can be used to tailor existing SL resins for particular applications.Mechanical Engineerin

Multi-Material Stereolithography: Spatially-Controlled Bioactive Poly(Ethylene Glycol) Scaffolds for Tissue Engineering

Challenges remain in tissue engineering to control the spatial and temporal mechanical and biochemical architectures of scaffolds. Unique capabilities of stereolithography (SL) for fabricating multi-material spatially-controlled bioactive scaffolds were explored in this work. To accomplish multi-material builds with implantable materials, a new mini-vat setup was designed, constructed and placed on top of the existing build platform to allow for accurate and selfaligning X-Y registration during fabrication. Precise quantities of photocrosslinkable solution were added to and removed from the mini-vat using micro-pipettes. The mini-vat setup allowed the part to be easily removed and rinsed and different photocrosslinkable solutions could be easily removed and added to the vat to aid in multi-material fabrication. Two photocrosslinkable hydrogel biopolymers, poly(ethylene glycol dimethacrylate) (PEG-dma, molecular wt 1,000) and poly(ethylene glycol)-diacrylate (PEG-da, molecular wt 3,400), were used as the primary scaffold materials, and controlled concentrations of fluorescently labeled dextran or bioactive PEG were prescribed and fabricated in different regions of the scaffold using SL. The equilibrium swelling behavior of the two biopolymers after SL fabrication was determined and used to design constructs with the specified dimensions at the swollen state. Two methods were used to measure the spatial gradients enabled by this process with multi-material spatial control successfully demonstrated down to 500-µm. First, the presence of the fluorescent component in specific regions of the scaffold was analyzed with fluorescent microscopy. Second, human dermal fibroblast cells were seeded on top of the fabricated scaffolds with selective bioactivity, and phase contrast microscopy images were used to show specific localization of cells in the regions patterned with bioactive PEG. The use of multi-material SL and the relative ease of conjugating different bioactive ligands or growth factors to PEG allows for the fabrication of tailored three-dimensional constructs with specified spatially-controlled bioactivity.Mechanical Engineerin

Numerical Study on the Recoating Process in Microstereolithography

Microstereolithography is a promising RP-based micro-fabrication technique that aims to meet the demands for complex geometry micro-scale parts. Projection microstereolithography incorporates a Dynamic Pattern Generator to obtain high resolution in the parallel plane. However, its lateral resolution has been always limited by the final layer thickness and the long resin settling time, both of which rely on the recoating process. In order to find the critical factors behind the recoating process, a numerical simulation method (Computational Fluid Dynamics, CFD) has been used to investigate the relationships among final layer thickness, settling time, resin viscosity and ratio of object/container size. These results are helpful for the selection of resin characteristics and the design of the microstereolithography machine.Mechanical Engineerin

Hydrogels in Stereolithography

The use of stereolithography (SL) for fabricating complex three-dimensional (3D) tissue engineered scaffolds of aqueous poly(ethylene glycol) (PEG) hydrogel solutions is described. The primary polymer used in the study was PEG-dimethacrylate (PEG-dma) with an average molecular weight (MW) of 1000 in distilled water with the photoinitiator Irgacure 2959 (I-2959). Successful layered manufacturing (LM) with embedded channel architecture required investigation of the photopolymerization characteristics of the PEG solution (measured as hydrogel thickness or cure depth) as a function of photoinitiator concentration and laser energy dosage for a specific photoinitiator type and polymer concentration in solution. Hydrogel thickness was a strong function of PI concentration and energy dosage. Curves of hydrogel thickness were utilized to successfully plan, perform, and demonstrate layered manufacturing of highly complex hydrogel scaffold structures, including structures with internal channels of various orientations. Successful fabrication of 3D, multi-layered bioactive PEG scaffolds containing cells was accomplished using a slightly modified commercial SL system (with 325 nm wavelength laser) and procedure. Human dermal fibroblast (HDF) cells were encapsulated in PEG hydrogels using small concentrations (~ 5 mg/ml) of acryloyl-PEG-RGDS (MW 3400) added to the photopolymerizable PEG solution to promote cell attachment. HDF cells were combined with the PEG solution, photocrosslinked using SL, and successfully shown to survive the fabrication process. The combined use of SL and photocrosslinkable biomaterials such as PEG makes it possible to fabricate complex 3D scaffolds that provide site-specific and tailored mechanical properties (i.e., multiple polymer materials) with a polymer matrix that allows transport of nutrients and waste at the macroscale and facilitates cellular processes at the microscale through precisely placed bioactive agents.Mechanical Engineerin