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Fabrication of 3D Polymer Micro components using DMD based Projection MSL

As demands for complex microstructures with high aspect ratios have increased, the existing
methods MEMS, LIGA and Scanning microstereolithography have the challenges coping
with the high aspect ratio, high process speed, low fabrication cost and repeatability.
Projection based microstereolithography technology can meet these demands because it is a
mask less fabricating process and is capable of fabricating high aspect ratio micro
components at greater speeds with good repeatability. In this work 3D part is fabricated by
stacking 2D layers which are obtained from STL file of CAD model. Dynamic image
projection enables the resin surface to be cured by dynamic image generated with Digital
Micro-mirror Device (DMD) in one radiation per layer.
Overall Scope & Modules:
Fabrication of 3D micro components using Digital Micro-mirror Device (DMD) based
projection micro-stereolithography (PSL) system.
Design and generation of CAD files for fabrication of 3D micro components.
Alignment of the system for best optical resolution for fabrication.
Optimization of process parameters for 3D micro component fabrication for high
aspect ratio.
Characterization of cured component for Dimensional accuracy and structural
integrity.