Exploring three-dimensional photoinhibition to enhance vat photopolymerization: A preliminary study

Vat photopolymerization (VPP) based additive manufacturing (AM) technologies print 3D components by using light to selectively cure photosensitive resins. In VPP-based AM, one outstanding challenge remains in controlling the over-curing, which is mainly caused by the diffusive and/or excessive photo-induced species such as free radicals and can severely affect the geometric properties of as-printed parts. Common practices rely on formulating proper resins or optimizing exposure parameters to address the vertical over-curing but often ignore the lateral over-curing. In this work, we develop a new VPP process of photoinhibition aided photopolymer AM (PinPAM) to comprehensively address over-curing issues in both vertical and lateral dimensions for enhancing the properties of as-printed geometry. The PinPAM method incorporates an adaptive photoinhibition zone, generated both surrounding and underneath the curing zone on a layer basis. This differs from current literature approaches that utilize photoinhibition to create a higher deadzone to increase print speed or constrain vertical profiles for achieving volumetric VPP AM. We present several preliminary experimental study cases involving pillar array sample printing. By comparing part dimensions and shapes resulting from traditional VPP and PinPAM, our experiments prove the concept of PinPAM and demonstrate its potential to address over-curing in VPP. Furthermore, we present an initial case study on optimizing the PinPAM process for printing cylinder samples with targeted dimensions, illustrating the planning and implementation of PinPAM. A discussion on future research directions to establish PinPAM is included. The developed PinPAM opens up a new avenue for improving VPP printed parts’ geometrical properties and facilitating its adoption in precision fabrications that demand dimensional accuracy and resolution.