Volumetric helical additive manufacturing

Abstract

3D printing has revolutionized the manufacturing of volumetric components and structures for various fields. Thanks to the advent of photocurable resins, several fully volumetric light-based techniques have been recently developed to overcome the current limitations of 3D printing. Although fast, this new generation of printers cannot fabricate objects whose size typically exceeds the centimeter without severely affecting the final resolution. Based on tomographic volumetric additive manufacturing, we propose a method for volumetric helical additive manufacturing (VHAM) multi-cm scale structures without magnifying the projected patterns. It consists of illuminating the photoresist while the latter follows a helical motion. This movement allows for increasing the height of the printable object. Additionally, we off-center the modulator used for projecting the light patterns to double the object's lateral size. We demonstrate experimentally the interest in using these two tricks for printing larger objects (up to 3 cm x 3 cm x 5 cm) while maintaining high resolution (<200 um) and short print time (<10 min).