Digital Light Processing System Research Articles

Digital light processing of yttria-stabilized zirconia: Modeling photoinitiator decay

A digital process was developed to facilitate additive manufacturing for ceramic materials using digital light processing (DLP). A numerical model that predicts DLP sample properties can be generated from manufacturing inputs to forecast the effect of resin age on mechanical strength of the printed part based on data collected from experiments. Key parameters for printing the green bodies included determining the depth of cure, layer thickness, material composition, and solids loading. Thermogravimetric analyses were used to develop debinding and sintering curves. Debinding is used to remove the volatile organics comprising the photopolymer resin. Sintering is performed after debinding to increase density and mechanical strength of the printed parts. The sintered parts were then subjected to characterization and mechanical testing. The ensemble of data for various DLP-printed ceramic materials were added to a database. A design of experiments can be generated from the manufacturing process defined in the database with selected changeable parameters randomized over a range. Because the database is defined with an architecture to capture manufacturing processes, it can persist as a more generic platform for manufacturing digital twins. This can ease the development of future digital twins and can grow as a common repository for the insights gained from manufacturing research. Creating a digital twin of a DLP system for 3D printing parts enables manufacturers to simulate and assess the impact of resin age on printing parameters and part quality, facilitating optimization, predictive maintenance, and cost reduction.

19‐1: Invited Paper: Zonal Illuminated Non‐emissive Displays for AR Glass

LCoS (Liquid Crystal on Silicon) and DLP (Digital Light Processing) are mature non‐emissive display technologies. Both conventional LCoS and DLP use global illumination so that the whole display panel is illuminated regardless of the content. Therefore,it has challenges of high power consumption, low contrast ratio and so on. In this paper, we proposed a zonal illuminated LCoS and DLP systems, which greatly improve the contrast ratio and reduce the gray box artifacts. In addition, it saves >3x power consumption for typical sparse AR content.

Performance measurements for indoor photovoltaic devices: Classification of a novel light source

There is an increasing interest in using indoor photovoltaic (IPV) devices to power Internet of Things applications, low power communications, and indoor environmental sensing. For the commercialization of IPV technologies, device performance measurements need to conform to the relevant standardized specifications. We present a novel IPV device measurement system that incorporates digital light processing (DLP) to deliver a spectrally invariant light source at all required illuminance levels, as specified by the indoor standard testing conditions in IEC TS 62607-7-2:2023. We evaluated the DLP system according to requirements for spectral coincidence, temporal stability, and non-uniformity at the sample plane. We demonstrate the measurements to define the classification status of the system and the unique benefits of the DLP system that allow a stable spectral profile and high levels of uniformity across all illuminance levels. This is the first reported measurement system for IPV device testing based on DLP technology, and the classification methodology of this work can be used as an example for the classification of indoor light simulators in laboratory environments based on the latest IEC TS 62607-7-2:2023.

Substrate-Independent Maskless Writing of Functionalized Microstructures Using CHic Chemistry and Digital Light Processing.

Maskless photolithography based on digital light processing (DLP) is an attractive technique for the rapid, flexible, and cost-effective fabrication of complex structures with arbitrary surface profiles on the microscale. In this work, we introduce a new material system for structure formation by DLP that is based on photoreactive polymers for the local and light-induced C,H-insertion cross-linking (CHic). This approach allows a simple and versatile generation of microstructures with a broad spectrum of geometries and chemistries irrespective of the nature of the chosen substrates and thus allows direct writing of surface functionalization patterns with high spatial control. The CHicable prepolymer is first coated on a substrate to form a solvent-free (glassy) film, and then the DLP system patterns the light with arbitrary shape to induce local cross-linking of the prepolymer. Using this method, the desired structures with complex features with a lateral resolution of several microns and a topography of tens of nanometers could be fabricated within 30 s. Furthermore, the universal applicability of the CHic reaction enables the printing on a wide variety of substrates, which greatly broadens the using scenarios of this printing approach.

Sequential process optimization for a digital light processing system to minimize trial and error

In additive manufacturing, logical and efficient workflow optimization enables successful production and reduces cost and time. These attempts are essential for preventing fabrication problems from various causes. However, quantitative analysis and integrated management studies of fabrication issues using a digital light processing (DLP) system are insufficient. Therefore, an efficient optimization method is required to apply several materials and extend the application of the DLP system. This study proposes a sequential process optimization (SPO) to manage the initial adhesion, recoating, and exposure energy. The photopolymerization characteristics and viscosity of the photocurable resin were quantitatively analyzed through process conditions such as build plate speed, layer thickness, and exposure time. The ability of the proposed SPO was confirmed by fabricating an evaluation model using a biocompatible resin. Furthermore, the biocompatibility of the developed resin was verified through experiments. The existing DLP process requires several trials and errors in process optimization. Therefore, the fabrication results are different depending on the operator’s know-how. The use of the proposed SPO enables a systematic approach for optimizing the process conditions of a DLP system. As a result, the DLP system is expected to be more utilized.

Digital Light Processing Bioprinting Advances for Microtissue Models.

Digital light processing (DLP) bioprinting has been widely introduced as a fast and robust biofabrication method in tissue engineering. The technique holds a great promise for creating tissue models because it can replicate the resolution and complexity of natural tissues and constructs. A DLP system projects 2D images onto layers of bioink using a digital photomask. The resolution of DLP bioprinting strongly depends on the characteristics of the projected light and the photo-cross-linking response of the bioink microenvironment. In this review, we present a summary of DLP fundamentals with a focus on bioink properties, photoinitiator selection, and light characteristics in resolution of bioprinted constructs. A simple guideline is provided for bioengineers interested in using DLP platforms and customizing technical specifications for its design. The literature review reveals the promising future of DLP bioprinting for disease modeling and biofabrication.

3D-printable colloidal photonic crystals

The architecture of the colloidal photonic crystals (CPCs) is of paramount importance to their functionality and applications. Nevertheless, the realization of CPCs with arbitrarily designed, volumetrically sophisticated structures at the macroscale remains challenging. In this work, a printable CPC ink was developed. By combining this ink with a digital light processing (DLP)-based three-dimensional (3D) printing system, we were able to fabricate the CPC superstructures featuring both digitally defined macroscale geometries and structural colors originating from the ordered structures at the sub-micron scale. Moreover, besides the arbitrarily adjustable and precisely designable architectures, the optical properties, mechanical performances, and stimuli-responsiveness of the printed objects could also be facilely tuned by the composition of the ink or the printing parameters of the DLP system. This technology endows us the ability to fabricate CPCs with a multitude of desirable functions as well as mimic the hierarchical structures and color-manipulation strategies of some creatures in nature, which paves the way for potentially broad applications in intelligent color displays, 3D integrated sensors, biomimetic color-morphing soft robots, and smart anti-counterfeiting labels, among others.

Three‐dimensional complex construct fabrication of illite by digital light processing‐based additive manufacturing technology

AbstractIllite is a group of clay minerals that are expected to be widely used in catalyst fabrication, radioactive element adsorption, and so forth, due to its excellent adsorption properties. However, the shape control limitation of the illite product should be overcome to maximize its utilization and properties. We herein propose additive manufacturing (AM) as one of the best solutions to solve this structural drawback. Digital light processing (DLP) technology with the film‐type of the material supplying system was adapted instead of the general vat‐type DLP system to increase illite printability. The photo‐curability and printability of illite‐contained photocurable suspension were optimized. The color effect due to different ferric oxide content in yellow‐ and white‐illite which influence the photopolymerization process also adjusted thoroughly. White illite showed better photo‐curability and could be increased solid loading than yellow illite. The defect‐free illite products with three‐dimensional complex structures, which cannot be produced by typical ceramic processes, were obtained by DLP technology for both yellow‐ and white‐illite after sintering at 1100°C. The overcoming of shape control limitation of illites by ceramic AM proved in this study has excellent potential for expanding illite utilities in various applications.

Bracket transfer accuracy with two different three-dimensional printed transfer trays vs silicone transfer trays.

To compare the transfer accuracy of two different three-dimensional printed trays (Dreve FotoDent ITB [Dreve Dentamid, Unna, Germany] and NextDent Ortho ITB [NextDent, Soesterberg, the Netherlands]) to polyvinyl siloxane (PVS) trays for indirect bonding. A total of 10 dental models were constructed for each investigated material. Virtual bracket placement was performed on a scanned dental model using OnyxCeph (OnyxCeph 3D Lab, Chemnitz, Germany). Three-dimensional printed transfer trays using a digital light processing system three-dimensional printer and silicone transfer trays were produced. Bracket positions were scanned after the indirect bonding procedure. Linear and angular transfer errors were measured. Significant differences between mean transfer errors and frequency of clinically acceptable errors (<0.25 mm/1°) were analyzed using the Kruskal-Wallis and χ2 tests, respectively. All trays showed comparable accuracy of bracket placement. NextDent exhibited a significantly higher frequency of rotational error within the limit of 1° (P = .01) compared with the PVS tray. Although PVS showed significant differences between the tooth groups in all linear dimensions, Dreve exhibited a significant difference in the buccolingual direction only. All groups showed a similar distribution of directional bias. Three-dimensional printed trays achieved comparable results with the PVS trays in terms of bracket positioning accuracy. NextDent appears to be inferior compared with PVS regarding the frequency of clinically acceptable errors, whereas Dreve was found to be equal. The influence of tooth groups on the accuracy of bracket positioning may be reduced by using an appropriate three-dimensional printed transfer tray (Dreve).

Fabrication of a porous hydroxyapatite scaffold with enhanced human osteoblast-like cell response via digital light processing system and biomimetic mineralization

In this study, we developed a photocurable hydroxyapatite (HA) slurry with 43 vol% HA content for a digital light processing (DLP) printing system. We assumed that the biomimetic mineralization coated on the surface of the DLP-printed porous HA scaffold could improve the in vitro cell response of the DLP-printed scaffold, such as in regards to cell adhesion or proliferation. Therefore, to verify the influence of biomimetic mineralization coated on the DLP-printed scaffold, the characteristics of the biomimetic mineralized HA scaffold (S-HA scaffold) were compared with those of HA bulk and HA scaffolds. It was found that the influences of the biomimetic mineralization on the structural characteristics of the HA scaffold were negligible, such as those on the apparent pore size, porosity, and compressive strength. However, the biomimetic mineralization coated on the surface of the HA scaffold improved the cell adhesion, proliferation, ALP activity, and gene expressions (runx2 and osteopontin) relative to the HA bulk and HA scaffolds, owing to the interconnected pores and increased nano-topology from the biomimetic mineralization. Therefore, we revealed that the in vitro cell response of a DLP-printed HA scaffold could be enhanced by biomimetic mineralization.

Adjusting the accuracy of PEGDA-GelMA vascular network by dark pigments via digital light processing printing.

Vascularization is one of the most important factors greatly influencing scaffold regeneration. In this study, a precise network of hollow vessels was printed by digital light processing (DLP) with poly(ethylene glycol) diacrylate (PEGDA)/gelatin-methacryloyl (GelMA), and dark pigmentation absorbers were added to ensure printing accuracy. First, the compound bio-inks of the PEGDA-GelMA hydrogel were prepared for direct vascular printing, and a high-precision DLP system was established. Second, the printing effects of three dark absorbers, namely, nigrosin, brilliant black, and brilliant blue, on the x-, y-, and z-axes were studied. By printing models with different densities, it was determined that 0.2% nigrosin, 0.1% brilliant black, and 0.3% brilliant blue had better effects on the x- and y-axes accuracy, and the absorbance of the absorbers played a decisive role in adjusting the accuracy. Additionally, to solve the problem of uneven curing on the upper and lower surfaces caused by the addition of an absorber with high absorbance, a model of the difference in curing width between the upper and lower surfaces of a unit-layer slice based on high-absorbance absorbers was established, and the reference value for the slice thickness was calculated. Third, the biological and mechanical properties of the bio-inks were verified with scanning electron microscopy and Fourier transform infrared, and by tensile, swelling, degradation, and cytotoxicity tests on different concentrations of PEGDA-GelMA hydrogel and absorbers. The results showed that 30% PEGDA-7% GelMA/0.1% brilliant black was the optimal preparation to print a hollow vascular network. The error of the printing tube wall and cavity was between 1% and 3%, which demonstrates the high precision of the method. Human umbilical vein endothelial cells were planted in the lumen, and the survival rate achieved 107% on the seventh day, demonstrating the good biocompatibility of the composite hydrogel.

A Three-Dimensional Liquid-Based Exchangeable Gradient Osmosis Chip for a Permeability Controllable Microfluidic Device

3D printing technology has significant potential for use in the field of microfluidics. Microfluidic chips are biochips that have been applied in biomedical areas such as disease diagnosis and drug delivery in vivo. However, traditional 2D manufacturing techniques limit the scope of their fabrication and usage. In addition, membrane-embedded microfluidic chips need intricately designed structures and well-defined nanofiber membranes for delivering specific drugs and filtering out impurities from blood, and it is difficult to respond quickly to the design and production of these complex three-dimensional shapes. Herein, we introduce a liquid-based exchangeable gradient osmosis (LEGO) chip comprising a 3D structured channel printed via a digital light processing system within 10 min and an electrospun nanofiber membrane. The attachment conditions of the nanofiber membranes to the 3D channel were optimized, while the permeability of specific materials was controlled by adjusting the concentration of nanofibers and the flow speed through the 3D channel. We anticipate that the LEGO chip will be used to produce bio-applicable devices for mass transfer in vivo.

A novel engineered vascular construct of stem cell-laden 3D-printed PGSA scaffold enhances tissue revascularization

Development of transplantable engineered tissue has been hampered by lacking vascular network within the engineered tissue. Three-dimensional (3D) printing has emerged as a new technology with great potential in fabrication and customization of geometric microstructure. In this study, utilizing digital light processing system, we manufactured a recently designed novel 3D architecture scaffold with poly(glycerol sebacate) acrylate (PGSA). Vascular construct was subsequently generated by seeding stem cells within this scaffold. PGSA provided inductive substrate in terms of supporting three-germ layer differentiation of embryonic stem cells (ESCs) and also promoting ESCs-derived vascular progenitor cells (VPCs) differentiation into endothelial cells (ECs). Furthermore, the differentiation efficiency of VPCs into ECs on PGSA was much higher than that on collagen IV or fibronectin. The results from seeding VPCs in the rotating hexagonal PGSA scaffold suggest that this architectural framework is highly efficient for cell engraftment in 3D structures. After long-term suspension culture of the VPCs in scaffold under directed EC differentiation condition, VPC-differentiated ECs were populated in the scaffold and expressed EC markers. Transplantation of the vascular construct in mice resulted in formation of new vascular network and integration of the microvasculature within the scaffold into the existing vasculature of host tissue. Importantly, in a mouse model of wound healing, ECs from the transplanted vascular construct directly contributed to revascularization and enhanced blood perfusion at the injured site. Collectively, this transplantable vascular construct provides an innovative alternative therapeutic strategy for vascular tissue engineering.

Stereolithography-Based Additive Manufacturing of High-Performance Osteoinductive Calcium Phosphate Ceramics by a Digital Light-Processing System.

Digital light processing (DLP) is one of the additive manufacturing (AM) technologies suitable for preparation of high-performance ceramics. The present study provided an optimized formula to fabricate osteoinductive calcium phosphate (CaP) ceramics with high precision and controllable three-dimensional (3D) structure. Among the four surfactants, monoalcohol ethoxylate phosphate was the best one to modify the CaP powders for preparing the photocurable slurry with high solid loading and good spreading ability. By testing the photopolymerization property of the 60 wt % solid loading slurry, the appropriate processing parameters including the slice thickness (50 μm), exposure intensity (10.14 mW/cm2), and exposure time (8 s) were set to perform the 3D printing of the ceramic green body in the DLP system. After the debinding and sintering, the final CaP ceramics were acquired. The stereomicroscope and SEM observation confirmed the high precision of the ceramics. The average compressive strength of the ceramics with 64.5% porosity reached 9.03 MPa. On only soaking in simulated body fluid for 1 day, an even layer of apatite formed on the ceramic surface. The cell culture confirmed that the ceramics could allow the good attachment, growth, and proliferation of murine bone marrow mesenchymal stem cells. After implantation into the dorsal muscles of beagle dogs for 3 months, abundant blood vessels and obvious ectopic bone formation were observed clearly by the histological evaluation. Therefore, with good bioactivity and osteoinductivity as well as high precision and adjustable mechanical strength, the 3D printed CaP ceramics in the DLP system could have good potential in customized bone-repairing applications.

Effect of the volume fraction of zirconia suspensions on the microstructure and physical properties of products produced by additive manufacturing

ObjectiveThe objectives of the present study were: (1) to analyze the dispersion and optical properties of suspensions with various volume fractions of zirconia, and (2) to assess the influence of zirconia volume fraction on the microstructure and physical properties of products produced by the additive manufacturing and sintering process. MethodsZirconia specimens were fabricated by an additive manufacturing technique using a DLP (digital light processing) system. The zirconia suspensions were divided into six groups based on zirconia volume fraction within the range of 48–58vol%. ResultsThe maximum volume fraction of zirconia in suspensions possible for printing was 58vol%. The cure depth of the zirconia suspensions decreased as the volume fraction increased. The cure depth was greater than 100μm after 15s photocuring in all groups. Geometrical overgrowth tended to increase gradually as the volume fraction of zirconia increased within the range of 28.55–36.94%. The 3-point bending strength of the specimens increased as the volume fraction of zirconia in the suspension increased, reaching a maximum value of 674.74±32.35MPa for a volume fraction of 58vol%. Cracks were observed on the surfaces of zirconia specimens and these cracks increased in number as zirconia volume fraction decreased. SignificanceIn this experiment, the viscosity of zirconia suspensions sharply increased from a volume fraction of 54vol%. Because of the very high viscosity, 58vol% was the maximum volume fraction possible for additive manufacturing. After polymerization, all specimens showed some distortion due to geometrical overgrowth. The maximum 3-point bending strength was 674.74±32.35MPa for a volume fraction of 58vol%. But the maximum strength of sintered zirconia prepared by additive manufacturing is inferior to that of conventionally sintered zirconia.

Biocompatibility of hydroxyapatite scaffolds processed by lithography-based additive manufacturing.

The fabrication of hydroxyapatite scaffolds for bone tissue engineering applications by using lithography-based additive manufacturing techniques has been introduced due to the abilities to control porous structures with suitable resolutions. In this research, the use of hydroxyapatite cellular structures, which are processed by lithography-based additive manufacturing machine, as a bone tissue engineering scaffold was investigated. The utilization of digital light processing system for additive manufacturing machine in laboratory scale was performed in order to fabricate the hydroxyapatite scaffold, of which biocompatibilities were eventually evaluated by direct contact and cell-culturing tests. In addition, the density and compressive strength of the scaffolds were also characterized. The results show that the hydroxyapatite scaffold at 77% of porosity with 91% of theoretical density and 0.36 MPa of the compressive strength are able to be processed. In comparison with a conventionally sintered hydroxyapatite, the scaffold did not present any cytotoxic signs while the viability of cells at 95.1% was reported. After 14 days of cell-culturing tests, the scaffold was able to be attached by pre-osteoblasts (MC3T3-E1) leading to cell proliferation and differentiation. The hydroxyapatite scaffold for bone tissue engineering was able to be processed by the lithography-based additive manufacturing machine while the biocompatibilities were also confirmed.

Ultr a thin Color Filter for Wearable Displays and Multispectral Imaging

We present a new approach to making in-pixel color filters for a wearable display such as LCOS (liquid crystal on silicon) or a DLP (digital light processing) system. Unlike current color filters or methods used in these devices, our approach enables Red-Green-Blue (RGB) color images using color filters fabricated using semiconductor ultra-thin film. These filters are less than 100 nm thick, making them better suited to integration with light modulators than traditional pigment-based filters. Additionally, these films are fabricated via e-beam evaporation or RF sputtering, which is compatible with most modern chip manufacturing. In this paper, we present the design concept for these filters, including simulation results that demonstrate improved liquid crystal control when using these filters, demonstrate an example RGB filter array and also present an enhanced structure which could meet requirements of DLP based multispectral imaging. This is the first time the use of these filters is presented for use in liquid crystal based displays and DLP.

Optical modulation of continuous terahertz waves towards cost-effective reconfigurable quasi-optical terahertz components

We report optical modulation of continuous terahertz (THz) wave in the frequency range of 570-600 GHz using photo-induced reconfigurable patterns on a silicon wafer. The patterns were implemented using programmable illumination from a commercially-available digital light processing (DLP) projector. A modulation depth of 20 dB at 585 GHz has been demonstrated. Modulation speed measurement shows a 3-dB bandwidth of ~1.3 kHz which is primarily limited by the DLP system. A photo-induced polarizer with tunable polarization angle has been demonstrated, showing a 3-dB extinction ratio. Reconfigurable aperture-arrays (4 x 4 pixels) have been attempted for room-temperature coded-aperture imaging using a single Schottky diode detector at 585 GHz. We envision that this technique will provide a simple but powerful means to realize a variety of cost-effective reconfigurable quasi-optical THz circuits and components.

DLP™-based dichoptic vision test system

It can be useful to present a different image to each of the two eyes while they cooperatively view the world. Such dichoptic presentation can occur in investigations of stereoscopic and binocular vision (e.g., strabismus, amblyopia) and vision rehabilitation in clinical and research settings. Various techniques have been used to construct dichoptic displays. The most common and most flexible modern technique uses liquid-crystal (LC) shutters. When used in combination with cathode ray tube (CRT) displays, there is often leakage of light from the image intended for one eye into the view of the other eye. Such interocular crosstalk is 14% even in our state of the art CRT-based dichoptic system. While such crosstalk may have minimal impact on stereo movie or video game experiences, it can defeat clinical and research investigations. We use micromirror digital light processing (DLP) technology to create a novel dichoptic visual display system with substantially lower interocular crosstalk (0.3%; remaining crosstalk comes from the LC shutters). The DLP system normally uses a color wheel to display color images. Our approach is to disable the color wheel, synchronize the display directly to the computer's sync signal, allocate each of the three (former) color presentations to one or both eyes, and open and close the LC shutters in synchrony with those color events.

Analysis and design of the color wheel in digital light processing system

Colorimetric characters are very important to the optical engine, the kernel of the projector. The equations to calculate the colorimetric characters of the color wheel in optical engine are proposed. They are proven by measurements and the calculation results. Based on this theory, the sensitivity of the spectral transmittance of the color filters to the chromaticity coordinates is analyzed. A conclusion on the color filters of the color wheel which is useful to the tolerance control is drawn. Finally, a color wheel system is designed by using the theory. The design can satisfy the specific of the original color wheel well.