3D printers working in the millimeter range and larger are increasingly used in industrial production processes. Many applications, however, require precise printing on the micrometer scale at a far higher speed.

Researchers of Karlsruhe Institute of Technology (KIT) have now developed a system to print highly precise, centimeter-sized objects with submicrometer details at a so far unmatched speed. This system is presented in a special issue of Advanced Functional Materials (DOI: 10.1002/adfm.201907795).

To demonstrate not only the speed, but also the reliability of their setup, the researchers have printed a lattice structure of 60 cubic millimeters in size with details down to the micrometer scale. It contains more than 300 billion voxels (a voxel is the 3D counterpart of a pixel or 2D picture element).

"We have by far outperformed the record reached by 3D-printed aircraft wings. This is a new world record," says Professor Martin Wegener, Spokesperson of the Cluster of Excellence "3D Matter Made to Order" (3DMM2O), within which the system was developed.

For this type of 3D printing, the beam of a laser passes a liquid photoresist in a computer-controlled manner. The material located in the focus of the laser only is exposed and hardened.

"The focal points correspond to the nozzles of an inkjet printer, the only difference being that they work three-dimensionally," Vincent Hahn, first author of the publication, says. In this way, highly precise filigree structures can be produced for various applications, such as optics and photonics, material sciences, bioengineering, or safety engineering. Typically, several hundred thousands of voxels per second have been produced with a single laser light spot so far.

This means that it was nearly a hundred times slower than graphical inkjet printers, which impeded many applications so far. Scientists of KIT and Queensland University of Technology (QUT) in Brisbane/Australia have now developed a new system within the 3DMM2O Cluster of Excellence.

Using special optics, the laser beam is divided into nine partial beams that focus on a focal point each. All nine partial beams can be used in parallel and, thanks to improved electronic control, they can be moved precisely much more rapidly than ever.

This and some other technical improvements made the researchers reach 3D printing speeds of about 10 million voxels per second, which corresponds to the speed reached by graphical 2D inkjet printers. KIT will continue research and development work in this area.

"After all, 3D printers will be used to print not just one page, but thick volumes," Hahn says. This will also require progress in chemistry. For example, more sensitive photoresists are needed to generate more focal points at the same laser output.

Research Report: "Rapid assembly of small materials building blocks (voxels) into large functional 3D metamaterials"

Related Links
Karlsruher Institute For Technology
Space Technology News - Applications and Research

Tweet

Thanks for being here; We need your help. The Space Media Network continues to grow but revenues have never been harder to maintain. With the rise of Ad Blockers, and Facebook - our traditional revenue sources via quality network advertising continues to decline. And unlike so many other news sites, we don't have a paywall - with those annoying usernames and passwords. Our news coverage takes time and effort to publish 365 days a year. If you find our news sites informative and useful then please consider becoming a regular supporter or for now make a one off contribution.
SpaceMediaNetwork Contributor $5 Billed Once credit card or paypal		SpaceMediaNetwork Monthly Supporter $5 Billed Monthly paypal only

"Breakthrough" 3D-printed rocket engine tests completed in Fife, Scotland
Edinburgh UK (SPX) Feb 04, 2020
The first ever eco liquid-fuel rocket engine ground tests to take place in Scotland have been deemed a huge success - and a major step forward in the UK's ambitions to become a space nation. Edinburgh-based satellite launch firm Skyrora has completed a week of static horizontal firings conducted in Fife to compare the behaviour of kerosene and eco-fuel. The test firings allowed Skyrora to assess its innovative 3D-printed 3.5kN LEO engine, which will be used to power the final upper stage of ... read more