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3D printing
The 3D printing industry has become a disruptive force, reshaping traditional manufacturing processes and opening up numerous possibilities. Also known as additive manufacturing, it involves layer-by-layer construction of objects from digital designs.
Initially used for prototyping, 3D printing has evolved into a mainstream solution for production, customization, and even medical applications. The market has grown exponentially, driven by advancements in materials, software, and printing technologies. With reduced costs and enhanced accessibility, businesses of all sizes are embracing 3D printing to streamline production, minimize waste, and accelerate innovation cycles.
From aerospace and automotive industries to healthcare and consumer goods, the versatility of 3D printing is transforming manufacturing paradigms. Photonics technology, in particular, plays a crucial role in this evolution by enhancing 3D printing capabilities with improved speed, precision, and resolution.
Enhancing high-resolution 3D printing with photonics technology
Photonics technology significantly advances 3D printing by enabling high-resolution additive manufacturing with improved speed and precision. Techniques such as two-photon polymerization (TPP)[1] and upconversion nanoparticles (UCNPs)[2][3] employ light-based methods to print complex objects with resolutions as fine as 100 nm. Additionally, multi-photon lithography allows for ultra-precise optical 3D printing, facilitating the creation of free-form geometries and miniature optical elements[4]. These advancements collectively drive the progression of 3D printing towards more efficient and versatile manufacturing capabilities.
Overview of 3D printing techniques
As shown below, 3D printing encompasses a diverse range of technologies, each offering unique methods that have evolved to accommodate various materials, production speeds, and levels of precision.
Stereolithography
(SLA)
(SLA)
Uses a laser to solidify layers of photosensitive resin, commonly employed for producing high-resolution prototypes. More recently UV LEDs are also being used for the purpose.
Selective laser melting
(SLM)
(SLM)
Precisely fuses metal or plastic powders using a laser, ideal for manufacturing complex components, increasingly used in aerospace, automotive and medical markets.
Laser-assisted fused deposition modeling (FDM)
Melts and deposits thermoplastic filaments layer by layer, widely utilized for rapid prototyping and low-cost production of consumer goods.
Selective laser sintering
(SLS)
(SLS)
Utilizes a laser to sinter plastic, metal, or ceramic powders, suitable for creating functional prototypes and end-use parts with high durability.
Binder jetting
Sprays a binding agent onto layers of powder material to form objects, often used for producing sand molds or metal parts with intricate geometries.
Directed energy deposition (DED)
Directs a focused energy source, such as a laser or electron beam, to melt and fuse metal powder or wire, commonly applied in aerospace and repair industries.
Each of these technologies has its own advantages and limitations, enabling a wide range of applications across industries such as aerospace, healthcare, automotive, and consumer goods. As technology continues to advance, innovations and improvements in 3D printing are expected to further expand its capabilities and reach.
Recommended products
LCOS-SLM technology in 3D metal printing offers several advantages that contribute to the overall quality of the final product. These include the ability to create complex geometries without specific dies or tools, reduced lead time from design to testing, decreased need for assemblies, and improved material utilization. Additionally, it eliminates the requirement for molds, reducing production time and costs while also enabling the production of parts with intricate structures like cavities and three-dimensional grids. It also ensures comparable mechanical load performance to traditional production methods like forging, ensuring high-quality end products.
Benefits of Hamamatsu’s LCOS-SLM X15213 series:
- Wide wavelengths: 400 to 2050 nm
- Laser power handling up to 750 W (in the spectral window 1000-1100 nm)
- High light utilization efficiency
- High-precision, high-linearity modulation characteristics for a specific wavelength
- High diffraction efficiency
UV LED curing technology is widely used in the 3D printing industry. It solidifies each layer of polymer material with ultraviolet light during the 3D printing process. Our portfolio of UV LED light sources covers the 280-405 nm spectral range, with our 365 nm spot LEDs recognized as the most powerful on the market.
These compact light sources can independently drive four heads yet are small enough to fit in the palm of your hand. The combination of 365 nm & 280 nm wavelengths enables optimum curing of UV resin and allows the removal of tack. The use of our high-efficiency UV curing adhesive with a narrow curing band and high photo-curing efficiency results in cured resin with excellent aging resistance and good toughness. The application of high-power 365 nm UV LEDs in UV curing processes optimizes energy accumulation and achieves desired irradiance intensity and spot profiles
Benefits of Hamamatsu’s UV-LED technology:
- Excellent 3D printing quality
- Guaranteed structural integrity of the part
- Reduced heat generation
The SPOLD (SPOt Laser Diode) is a fiber coupled semiconductor laser source with an integrated driver and cooling system in a compact package. The laser irradiation is delivered via distal interchangeable lens for either circular or linear beam profiles.
The importance of wavelengths
The specific wavelengths of continuous wave (CW) lasers are crucial for optimum interaction with various materials. This enables applications such as 3D printing, plastic welding, hermetic sealing, thermal curing of adhesives, glass sealing, and sintering of metallic inks. Selecting the right wavelength ensures maximum efficiency, particularly for polymers and composites, where it influences selective material absorption.
Benefits of Hamamatsu’s SPOLD:
- Wide power range from 9W to 360W with several wavelengths
- 'Top hat beam profile' for uniform intensity distribution
- Compact, customizable, easy to operate andequipped with in-built temperature monitoring
NIR semiconductor lasers offer promising developments in 3D printing. In addition to the benefits stated above, they can initiate cross-linking directly at the focal point, showcasing the potential for low-cost direct laser writing in volume and 3D printing. NIR lasers can also be integrated into ink-based 3D printing technologies to solidify filaments with diameters up to 4 mm, surpassing the limitations of UV-based curing in terms of range and intensity.
References
[1] Q. Zhang, A. Boniface, V. K. Parashar, and C. Moser, "Multiphoton polymerization using upconversion nanoparticles for adaptive high-resolution 3D printing," vol. 12433, pp. 124330C-124330C, 2023, doi: 10.1117/12.2650323.
[2] "Multi-photon polymerization using upconversion nanoparticles for tunable feature-size printing," 2022, doi: 10.48550/arxiv.2211.01437.
[3] "Micro‐Optics 3D Printed via Multi‐Photon Laser Lithography (Advanced Optical Materials 1/2023)," Adv. Opt. Mater., vol. 11, no. 1, pp. 2370001-2370001, 2023, doi: 10.1002/adom.202370001.
[4] Lovera, M. O. Giacone, C. G. E. Alfieri, E. Casamenti, and R. Ferrini, "3D printing of glass micro-devices for integrated photonics and miniaturized optics," 2023, doi: 10.1117/12.2649093.
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