Photopolymer formulation to minimize feature size, surface roughness, and stair-stepping in digital light processing-based three-dimensional printing

Abstract

Achievement of optimized lateral and vertical resolution is a key factor to obtaining three-dimensional (3D) structural details fabricated through digital light processing (DLP)-based 3D printing technologies which exploit digitalized ultraviolet (UV) or near-UV light to trigger localized photopolymerization forming solid patterns from liquid polymer resins. Many efforts have been made to optimize printing resolution through improving the optical systems. However, researchers have paid comparatively little attention to understand the influences of polymer formulation on the printing resolution and surface quality. Here, we report an investigation on the effects of in-house formulated (meth)acrylate-based photopolymer constituent types and concentrations on the resolution and quality of structures printed on a bottom-exposure DLP-based 3D printing system. We examined a wide variety of resin formulations to determine optimal formulations that yield best printing resolution and surface quality over a reasonably broad range of mechanical properties. We demonstrated the controlled fabrication of sub-pixel conical and aspherical smooth features, whereby the shape and dimensions could be prescribed with the resin formulation and process parameters. Such features hold promising implications in micro-optic and microfluidic fabrication using the DLP-based 3D printing technique. Additionally, we devised di(meth)acrylate-based resin formulations which could exclusively produce optically-clear layers in contrast to opaque, rough surfaces resulting from commonly-used diacrylate-based resins including those available commercially. Use of this solution minimized the ‘stair-stepping’ effect in components printed in a layer-by-layer manner. We also showed that the maximum lateral and vertical resolution attainable using our present system were 7 μm and 4 μm, respectively, while maintaining uniform width and height. Taken together, the present findings provide a basis for optimized photopolymer resin formulations that retain maximum vertical and lateral resolutions and minimal surface roughness and layering artifacts for a versatile range of mechanical and rheological properties suited to novel applications in 3D printing of smooth free-form solids, micro-optics, and direct fabrication of microfluidic platforms with functional surfaces.