Cross-scale light curing 3D printing method based on dynamic projection scanning lithography

Purpose In this paper, a dynamic projection scanning lithography (DPSL) technology and system is proposed to achieve cross-scale 3D printing, addressing the limitations of the traditional 3D printing methods that struggle to achieve both large build volumes and high precision. The method achieves a printing accuracy of 10 µm within a build volume of 100 × 100 × 100 mm, and successfully fabricates complex hollow structures and functional models. Design/methodology/approach DPSL uses a digital micromirror device (DMD)-based digital projector to generate light patterns for light-curing printing. The light patterns are created by sequentially loading the print design frame by frame, forming dynamic light patterns that are scanned line by line across the material surface for solidifying the printing materials. By controlling the scanning range of the digital projector, it is theoretically able to print models of any size. Additionally, by using DMD oblique scanning, the impact of the DMD micromirrors’ shape and arrangement on print accuracy is addressed by overlapping exposures along the scanning direction of the digital projector. Findings This study shows the printing system resolution of 1.3 µm, while the maximum size of the printing model depends on the system scanning range. Additionally, by using DMD oblique scanning, the impact of the DMD micromirrors’ shape and arrangement on print accuracy is addressed by overlapping exposures along the scanning direction of the digital projector. Originality/value This work demonstrates that DPSL based on oblique scanning technology is used to achieve 3D printing with high precision, large area and smoother surface. In addition, a rigid release method is used to achieve a precise printing layer thickness in the top-down printing process. By adhering the release film to the bottom surface of the glass and adjusting the descent distance of the stage for each layer, uniform layer thickness can be achieved for each exposure.