Spatial Light Modulator-based printing technologies for optical elements fabrication with different materials

Abstract

Spatial Light Modulator (SLM)-based printing technologies, including Digital Light Processing (DLP) and Liquid Crystal Display (LCD), have emerged as transformative solutions for the fabrication of high-precision optical elements. These technologies address the increasing demand for customizable, high-performance optical components in fields like telecommunications, biomedical optics, imaging systems, and optical computing. By enabling the rapid production of complex structures with exceptional accuracy and scalability. This review aims to provide a comprehensive analysis of recent advancements in SLM-based printing technologies, with a particular focus on innovations that enhance fabrication precision, material versatility, and production efficiency. Key innovations (developments) such as overlapping superposition, volumetric additive manufacturing, and Continuous Liquid Interface Production (CLIP) are examined for their role in improving profile fidelity, reducing process-induced artifacts, and expanding the range of manufacturable optical geometries. Additionally, this review explores the wide range of photo-curing materials, from organic polymers to advanced hybrid composites such as “Liquid Glass” and SOL-GEL materials, which are expanding the material capabilities including optical and mechanical properties for SLM technologies. The review also addresses critical challenges in critical manufacturing techniques and investigates precision-enhancing strategies, such as defocus DLP stereolithography, fluid-forming, and frame constraint molding, which tackle challenges in precision, surface smoothness, and scalability. Finally, the review examines the future directions of SLM-based printing technologies, emphasizing their potential to revolutionize optical component fabrication and drive innovations in next-generation optical devices.