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

builds Ameya Limaye and Dr. David Rosen George W. Woodruff School of Mechanical Engineering Georgia Institute of Technology Atlanta GA 30332 Contact: Telephone number: 404 894 9668 Email: david.rosen@me.gatech.edu Reviewed, accepted August 26, 2005 Abstract 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.

[1]  Serge Monneret,et al.  Micro-scale rapid prototyping by stereolithography , 2001, ETFA 2001. 8th International Conference on Emerging Technologies and Factory Automation. Proceedings (Cat. No.01TH8597).

[2]  Peter J. Hesketh,et al.  Stereolithography on silicon for microfluidics and microsensor packaging , 2003 .

[3]  Christian Vogt,et al.  Rapid prototyping of small size objects , 2000 .

[4]  Philip Birch,et al.  A novel high-accuracy microstereolithography method employing an adaptive electro-optic mask , 2000 .

[5]  Philippe Renaud,et al.  Microstereolithography: a new process to build complex 3D objects , 1999, Design, Test, Integration, and Packaging of MEMS/MOEMS.

[6]  Walter M. Duncan,et al.  Emerging digital micromirror device (DMD) applications , 2003, SPIE MOEMS-MEMS.

[7]  Philippe Renaud,et al.  Microstereolithography: concepts and applications , 2001, ETFA 2001. 8th International Conference on Emerging Technologies and Factory Automation. Proceedings (Cat. No.01TH8597).

[8]  Hongseok Choi,et al.  Digital Micromirror Device Based Microstereolithography for Micro Structures of Transparent Photopolymer and Nanocomposites , 2003 .

[9]  P Birch,et al.  Microfabrication by use of a spatial light modulator in the ultraviolet: experimental results. , 1999, Optics letters.

[10]  P Birch,et al.  UV Microstereolithography System that uses Spatial Light Modulator Technology. , 1998, Applied optics.

[11]  M. I. Heywood,et al.  Characterisation of Epoxy Resins for Microstereolithographic Rapid Prototyping , 1999 .

[12]  Hubert Lorenz,et al.  3D microfabrication by combining microstereolithography and thick resist UV lithography , 1999 .

[13]  Warren D. Smith,et al.  Modern Optical Engineering: The Design of Optical Systems, Fourth Edition , 1966 .

[14]  M. Madou.  Fundamentals of microfabrication , 1997 .

[15]  Paul F. Jacobs,et al.  Rapid Prototyping & Manufacturing: Fundamentals of Stereolithography , 1992 .

[16]  Ameya Shankar Limaye.  Design and Analysis of a Mask projection Micro Stereolithography System , 2004 .

[17]  Serge Monneret,et al.  Microstereolithography using a dynamic mask generator and a noncoherent visible light source , 1999, Design, Test, Integration, and Packaging of MEMS/MOEMS.

[18]  S. Zissi,et al.  Microstereophotolithography using a liquid crystal display as dynamic mask-generator , 1997 .

[19]  藤正 巌.  Micromachines : a new era in mechanical engineering , 1996 .

[20]  David W. Rosen,et al.  Quantifying Dimensional Accuracy of a Mask Projection Micro Stereolithography System , 2004 .