Results of an interlaboratory study on the working curve in vat photopolymerization.

The working curve informs resin properties and print parameters for stereolithography, digital light processing, and other photopolymer additive manufacturing (PAM) technologies. First demonstrated in 1992, the working curve measurement of cure depth vs radiant exposure of light is now a foundational measurement in the field of PAM. Despite its widespread use in industry and academia, there is no formal method or procedure for performing the working curve measurement, raising questions about the utility of reported working curve parameters. Here, an interlaboratory study (ILS) is described in which 24 individual laboratories performed a working curve measurement on an aliquot from a single batch of PAM resin. The ILS reveals that there is enormous scatter in the working curve data and the key fit parameters derived from it. The measured depth of light penetration Dp varied by as much as 7x between participants, while the critical radiant exposure for gelation Ec varied by as much as 70x. This significant scatter is attributed to a lack of common procedure, variation in light engines, epistemic uncertainties from the Jacobs equation, and the use of measurement tools with insufficient precision. The ILS findings highlight an urgent need for procedural standardization and better hardware characterization in this rapidly growing field.

Characterizing light engine uniformity and its influence on liquid crystal display based vat photopolymerization printing.

Vat photopolymerization (VP) is a rapidly growing category of additive manufacturing. As VP methods mature the expectation is that the quality of printed parts will be highly reproducible. At present, detailed characterization of the light engines used in liquid crystal display (LCD)-based VP systems is lacking and so it is unclear if they are built to sufficiently tight tolerances to meet the current and/or future needs of additive manufacturing. Herein, we map the irradiance, spectral characteristics, and optical divergence of a nominally 405 nm LCD-based VP light engine. We find that there is notable variation in all of these properties as a function of position on the light engine that cause changes in extent of polymerization and surface texture. We further demonstrate through a derived photon absorption figure of merit and through printed test parts that the spatial heterogeneity observed in the light engine is significant enough to affect part fidelity. These findings help to explain several possible causes of variable part quality and also highlight the need for improved optical performance on LCD-based VP printers.

Eliminating the middleman: ultraviolet scale realization using a laser-driven plasma light source.

After we replaced the argon mini-arc with a laser-driven light source in the Ultraviolet Spectral Comparator Facility at the National Institute of Standards and Technology (NIST), we realized that the optical power should be sufficient to use the comparator system for absolute-cryogenic radiometry. Calibrating working standard detectors directly against an absolute-cryogenic radiometer in the system used for calibrations would eliminate all uncertainties resulting from the use of transfer standards, which were calibrated in a separate system using a different light source and optics. The transfer standards are the middlemen we refer to in the title. Any uncertainty caused by differences in bandpass, out-off-band radiation, spectral purity, collimation, or data interpolation would be removed. In the end, we successfully set up a twin system resembling the Ultraviolet Spectral Comparator Facility and used this system to perform a primary calibration of several photodiodes, based on an absolute-cryogenic radiometer. Using this system, we were able to reduce relative standard uncertainties at wavelengths below 220 nm from above 1 % (k=1) to below 0.5%. We refer to this system as the Ultraviolet Scale Realization Facility or UV-SRF.

Invited Article: Refined analysis of synchrotron radiation for NIST's SURF III facility.

We have developed a new method for the exact calculation of synchrotron radiation for the National Institute of Standards and Technology Synchrotron Ultraviolet Radiation Facility, SURF III. Instead of using the Schwinger formula, which is only an approximation, we develop formulae based on Graf's addition theorem for Bessel functions and accurate asymptotic expansions for Hankel functions and Bessel functions. By measuring the radiation intensity profile at two distances from the storage ring, we also confirm an apparent vertical emittance that is consistent with the vertical betatron oscillations that are intentionally introduced to extend beam lifetime by spreading the electron beam spatially. Finally, we determine how much diffraction by beamline apertures enhances the spectral irradiance at an integrating sphere entrance port at the end station. This should eliminate small but treatable components of the uncertainty budget that one should consider when using SURF III or similar synchrotrons as standard, calculable sources of ultraviolet and other radiation.

Argon mini-arc meets its match: use of a laser-driven plasma source in ultraviolet-detector calibrations.

The National Institute of Standards and Technology operates two spectral comparator facilities, both of which are used to provide detector calibrations from the ultraviolet to the near-infrared spectral range. One, the Ultraviolet Spectral Comparator Facility (UV SCF), has been in operation for more than two decades, providing one of the core calibration services. Recently, the illumination source used in the UV SCF has been changed from an argon mini-arc source to a laser-driven plasma light source. This new source has higher brightness, a smaller source size, better temporal stability, and much better conversion efficiency than the previous source. The improvements in the capabilities are summarized.

Ultraviolet characterization of integrating spheres.

We have studied the performance of polytetrafluoroethylene integrating spheres in the ultraviolet (UV) region with wavelengths as short as 200 nm. Two techniques were used for this study; first, the spectral throughput of an integrating sphere irradiated by a deuterium lamp was analyzed by a monochromator. Second, a UV laser beam was directed into an integrating sphere, and spectrally dispersed laser induced fluorescence was studied. Significant absorption and fluorescence features were observed in the UV region and attributed to the contamination in the integrating sphere. We demonstrate that integrating spheres are easily contaminated by environmental pollutants such as polycyclic aromatic hydrocarbons emitted from engine exhaust. Baking of the contaminated integrating sphere can reverse some but not all of the effects caused by contaminants. The implications for using integrating spheres for UV measurement are discussed.

Synchrotron radiation-based irradiance calibration from 200 to 400 nm at the Synchrotron Ultraviolet Radiation Facility III.

A new facility for measuring irradiance in the UV was commissioned recently at the National Institute of Standards and Technology (NIST). The facility uses the calculable radiation from the Synchrotron Ultraviolet Radiation Facility as the primary standard. To measure the irradiance from a source under test, an integrating sphere spectrometer-detector system measures both the source under test and the synchrotron radiation sequentially, and the irradiance from the source under test can be determined. In particular, we discuss the calibration of deuterium lamps using this facility from 200 to 400 nm. This facility improves the current NIST UV irradiance scale to a relative measurement uncertainty of 1.2% (k=2).