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Controlling Light in Scattering Materials for Volumetric Additive Manufacturing

Antoine Vincent Boniface, Paul Delrot, Damien Claude-Marie Loterie, Jorge Andres Madrid Wolff, Christophe Moser

3D printing has revolutionized the manufacturing of volumetric components and structures in many areas. Several fully volumetric light-based techniques have been recently developed thanks to the advent of photocurable resins, promising to reach unprecedented short print time (down to a few tens of seconds) while keeping a good resolution (around 100 mu m). However, these new approaches only work with homogeneous and relatively transparent resins so that the light patterns used for photo-polymerization are not scrambled along their propagation. Herein, a method that takes into account light scattering in the resin prior to computing projection patterns is proposed. Using a tomographic volumetric printer, it is experimentally demonstrated that implementation of this correction is critical when printing objects whose size exceeds the scattering mean free path. To show the broad applicability of the technique, functional objects of high print fidelity are fabricated in hard organic scattering acrylates and soft cell-laden hydrogels (at 4 million cells mL(-1)). This opens up promising perspectives in printing inside turbid materials with particular interesting applications for bioprinting cell-laden constructs.

WILEY2022

High resolution and three-dimensional printing in complex photosensitive materials

Antoine Vincent Boniface, Christophe Moser

The present invention is related to a method of volumetric manufacturing a three-dimensional object or article by illuminating a non-transparent and/or absorptive photo-sensitive material with light patterns from multiple angles, comprising the steps of capturing at least one fluorescence or scattering snapshot for one or a set of different illuminating projected patterns in the said photo-sensitive material, obtaining therefrom at least one physical parameter describing the light propagation through the said photo-sensitive material, and computing a set of optimized projected patterns with the aid of the at least one physical parameter, wherein said optimized projected patterns (204) are used for volumetric manufacturing said three-dimensional object or article. The present invention is furthermore related to a device for performing said method.

2022

Tomographic Volumetric Additive Manufacturing of Silicon Oxycarbide Ceramics

Antoine Vincent Boniface, Jürgen Brugger, Paul Delrot, Lorenz Hagelüken, Max Kollep, Georgia Konstantinou, Damien Claude-Marie Loterie, Jorge Andres Madrid Wolff, Christophe Moser

Ceramics are highly technical materials with properties of interest for multiple industries. Precisely because of their high chemical, thermal, and mechanical resistance, ceramics are difficult to mold into complex shapes. A possibility to make convoluted ceramic parts is to use preceramic polymers (PCP) in liquid form. The PCP resin is first solidified in a desired geometry and then transformed into ceramic compounds through a pyrolysis step that preserves the shape. Light-based additive manufacturing (AM) is a promising route to achieve solidification of the PCP resin. Different approaches, such as stereolithography, have already been proposed but they all rely on a layer-by-layer printing process which sets limitations on the printing speed and object geometry. Here, we report on the fabrication of complex 3D centimeter-scale ceramic parts by using tomographic volumetric printing, which is fast and offers a high resolution and geometrical design freedom. First, we formulated a photosensitive preceramic resin that was solidified by projecting light patterns from multiple angles. Then, the obtained 3D printed parts were converted into ceramics by pyrolysis. We demonstrate the strength of this approach through the fabrication of dense microcomponents exhibiting overhangs and hollow geometries without the need of supporting structures, and characterize their resistance to thermal stress and harsh chemical treatments.

2022