Continuous Volumetric 3D Printing: Xolography in Flow

Advanced Materials, vol. 36, pp. e2306716

Abstract

Abstract Additive manufacturing techniques continue to improve in resolution, geometrical freedom, and production rates, expanding their application range in research and industry. Most established techniques, however, are based on layer‐by‐layer polymerization processes, leading to an inherent trade‐off between resolution and printing speed. Volumetric 3D printing enables the polymerization of freely defined volumes allowing the fabrication of complex geometries at drastically increased production rates and high resolutions, marking the next chapter in light‐based additive manufacturing. This work advances the volumetric 3D printing technique xolography to a continuous process. Dual‐color photopolymerization is performed in a continuously flowing resin, inside a tailored flow cell. Supported by simulations, the flow profile in the printing area is flattened, and resin velocities at the flow cell walls are increased to minimize unwanted polymerization via laser sheet‐induced curing. Various objects are printed continuously and true to shape with smooth surfaces. Parallel object printing paves the way for up‐scaling the continuous production, currently reaching production rates up to 1.75 mm 3 s −1 for the presented flow cell. Xolography in flow provides a new opportunity for scaling up volumetric 3D printing with the potential to resolve the trade‐off between high production rates and high resolution in light‐based additive manufacturing.

Authors 7

1. Lucas Stüwe Aachen Chemical Process Engineering

   RWTH Aachen University

   Affiliation as printed

   Chemical Process Engineering RWTH Aachen University Forckenbeckstr. 51 52074 Aachen Germany

   Chemical Process Engineering, RWTH Aachen University, Forckenbeckstr. 51, 52074 Aachen, Germany

2. Matthias Florian Geiger Aachen Chemical Process Engineering

   RWTH Aachen University

   Affiliation as printed

   Chemical Process Engineering RWTH Aachen University Forckenbeckstr. 51 52074 Aachen Germany

   Chemical Process Engineering, RWTH Aachen University, Forckenbeckstr. 51, 52074 Aachen, Germany

3. Franz W. Röllgen Aachen Chemical Process Engineering

   RWTH Aachen University

   Affiliation as printed

   Chemical Process Engineering RWTH Aachen University Forckenbeckstr. 51 52074 Aachen Germany

   Chemical Process Engineering, RWTH Aachen University, Forckenbeckstr. 51, 52074 Aachen, Germany

4. Thorben Heinze Aachen Chemical Process Engineering

   RWTH Aachen University

   Affiliation as printed

   Chemical Process Engineering RWTH Aachen University Forckenbeckstr. 51 52074 Aachen Germany

   Chemical Process Engineering, RWTH Aachen University, Forckenbeckstr. 51, 52074 Aachen, Germany

5. Matthias Weßling Aachen Chemical Process Engineering DWI - Leibniz Institute for Interactive Materials

   DWI – Leibniz Institute for Interactive Materials · RWTH Aachen University

   Affiliation as printed

   Chemical Process Engineering RWTH Aachen University Forckenbeckstr. 51 52074 Aachen Germany

   DWI–Leibniz Institute for Interactive Materials Forckenbeckstr. 50 52074 Aachen Germany

   Chemical Process Engineering, RWTH Aachen University, Forckenbeckstr. 51, 52074 Aachen, Germany

   DWI - Leibniz Institute for Interactive Materials, Forckenbeckstr. 50, 52074 Aachen, Germany

6. Stefan Hecht corresponding Aachen DWI - Leibniz Institute for Interactive Materials

   Humboldt-Universität zu Berlin · DWI – Leibniz Institute for Interactive Materials

   Affiliation as printed

   DWI–Leibniz Institute for Interactive Materials Forckenbeckstr. 50 52074 Aachen Germany

   Department of Chemistry Humboldt‐Universität zu Berlin Brook‐Taylor‐Street 2 12489 Berlin Germany

   DWI - Leibniz Institute for Interactive Materials, Forckenbeckstr. 50, 52074 Aachen, Germany

7. John Linkhorst corresponding Aachen Chemical Process Engineering

   RWTH Aachen University

   Affiliation as printed

   Chemical Process Engineering RWTH Aachen University Forckenbeckstr. 51 52074 Aachen Germany

   Chemical Process Engineering, RWTH Aachen University, Forckenbeckstr. 51, 52074 Aachen, Germany