Influence of Spectral Bandwidth on the Working Curve in Vat Photopolymerization.

In vat photopolymerization, 3-dimensional parts are fabricated by using patterned light to spatially cure a liquid resin. One of the foundational measurements for vat photopolymerization is known as the working curve whereby the depth (i.e. thickness) of cured resin is measured as a function of radiant exposure. The commonly applied mathematical model for the working curve - known widely as the Jacobs model - assumes a monochromatic light source. The Jacobs model has been widely used, but in many cases significant deviations between the Jacobs model and the data have been observed. Herein, we extend the Jacobs model by deriving a polychromatic model that accounts for broadband light sources (e.g. light emitting diodes, LEDs). We demonstrate through experiment and theory that in certain cases the deviations from Jacobs' original model can be explained and understood as an optical 'inner filter' effect. The ability of the Jacobs model to capture the working curve behavior is shown to be dependent on the bandwidth of the light source in conjunction with the gradient in the absorption spectrum of the resin in the vicinity of the light source spectrum. Additionally, we offer an empirical model function that better fits experimental data and allows for an improved estimate of model parameters. Broadly, this work aims to strengthen the conceptual link between the working curve measurement and the photophysical parameters that are intrinsic to vat photopolymerization printing.

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.