Researchers from the École Polytechnique Fédérale de Lausanne (EPFL) have launched a compact, high-efficiency holographic tomographic volumetric additive manufacturing (HT-VAM) system that leverages a MEMS-based phase-only mild modulator. This improvement marks a major development in addressing the sunshine supply limitations related to volumetric 3D printing.Their work, detailed in a preprint on arXiv (June 2025) demonstrates how section modulation can revolutionize light-based fabrication, enabling sooner, higher-resolution prints with unprecedented vitality effectivity.
Holography meets volumetric manufacturing
Volumetric Additive Manufacturing (VAM) is a layerless 3D printing approach that cures whole objects concurrently by projecting mild patterns right into a rotating vial of photoresin. Not like layer-by-layer strategies, VAM eliminates stair-stepping artifacts and allows support-free fabrication of complicated geometries. EPFL’s strategy, Tomographic VAM (TVAM), adapts computed tomography rules to generate dynamic mild fields that polymerize resin volumetrically.
Conventional TVAM programs usually depend on Digital Micromirror Gadgets (DMDs), binary amplitude modulators with restricted mild effectivity, sometimes beneath 10%. The EPFL group replaces these with a phase-only Part Gentle Modulator (PLM), which allows exact wavefront management. This transformation leads to a measured mild effectivity of 23.78%, representing a 70× enchancment over DMDs, whereas additionally lowering imaging artifacts like speckle noise.
Part Modulation: A Recreation Changer
Till not too long ago, Liquid Crystal on Silicon (LCOS) Spatial Gentle Modulators (SLMs) had been the usual for section modulation. Nonetheless, LCOS suffers from limitations together with gradual response occasions (60–120 Hz), ultraviolet (UV) degradation, and polarization sensitivity.
In distinction, EPFL’s MEMS-based PLM, developed by Texas Devices, makes use of piston-motion micromirrors to encode section instantly. It encompasses a 4-bit decision (16 section ranges) for exact wavefront shaping, excessive pace (1,440 Hz body charge) for speedy patterning and polarization insensitivity and UV stability, vital for photopolymerization.
This structure allows using low-power, single-mode 405 nm lasers, reducing each price and system complexity whereas reaching near-theoretical diffraction effectivity.
Speckle Discount and Print High quality
A key innovation lies within the system’s speckle-reduction pipeline. Speckle, attributable to interference in coherent mild, was mitigated via time-multiplexed projection of 9 laterally shifted holograms per angle. Mixed with Bessel beam axicon phases, this diminished speckle distinction by 50% (from 0.45 to 0.33) and prolonged the system’s depth of focus, making certain uniform decision all through the print quantity.
Speedy, high-fidelity printing
The system demonstrated speedy printing of complicated fashions, corresponding to a 4 mm fusilli pasta construction in 32 seconds (18 mW laser energy), a Stanford Bunny (8 mm tall) in 61 seconds (50 mW) and DNA helices with easy surfaces at micrometer scales. Potential functions span bioprinting, micro-optics, and aerospace, the place pace, decision, and materials effectivity are vital.
Volumetric printing matures with improvements in mild management and biomedical functions
Volumetric additive manufacturing has gained momentum as a promising different to conventional layer-by-layer 3D printing, providing the power to manufacture whole objects concurrently with fewer constraints on geometry and pace. Latest advances embody automated publicity management programs for extra exact mild dosing throughout tomographic projection, and using light-converting nanoparticles to allow deeper and extra managed polymerization. Swiss agency Readily3D, a spin-off from EPFL, has additionally superior volumetric bioprinting via its collaborations with BIO INX, aiming to simplify the fabrication of complicated organic fashions.
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Featured picture reveals floor high quality enchancment comparability. Picture through Laboratory of Utilized Photonics Gadgets (LAPD), EPFL.
