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 currently available. The developed process is based on a mask-image-projection-based Stereolithography process (MIP-SL), during which a Digital Micromirror Device (DMD) controlled projection light cures and cross-links liquid photopolymer resin. In order to achieve high-speed fabrication, we investigated the bottom-up projection system in the MIP-SL process. A set of techniques including film coating and the combination of two-way linear motions have been developed for the quick spreading of liquid resin into uniform thin layers. The process parameters and related settings to achieve the fabrication speed of a few seconds per layer are presented. Additionally, the hardware, software, and material setups developed for fabricating given 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.
- Manufacturing Engineering Division
Rapid Manufacturing in Minutes: The Development of a Mask Projection Stereolithography Process for High-Speed Fabrication
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Pan, Y, Zhou, C, & Chen, Y. "Rapid Manufacturing in Minutes: The Development of a Mask Projection Stereolithography Process for High-Speed Fabrication." Proceedings of the ASME 2012 International Manufacturing Science and Engineering Conference collocated with the 40th North American Manufacturing Research Conference and in participation with the International Conference on Tribology Materials and Processing. ASME 2012 International Manufacturing Science and Engineering Conference. Notre Dame, Indiana, USA. June 4–8, 2012. pp. 405-414. ASME. https://doi.org/10.1115/MSEC2012-7232
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