JP2022064974A - 3d付加製造のためのコンピュータアキシャルリソグラフィ(cal)のためのシステムおよび方法 - Google Patents
3d付加製造のためのコンピュータアキシャルリソグラフィ(cal)のためのシステムおよび方法 Download PDFInfo
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Abstract
Description
米国政府は、ローレンスリバモア国立研究所の運営のために、米国エネルギ省とローレンスリバモアナショナルセキュリティLLCとの間の契約番号DE-AC52-07NA27344に従って、本発明において権利を有する。
本開示は、付加製造を実行するためのシステムおよび方法に関し、より詳細には、コンピュータ断層撮影(CT)技術を使用する体積製造(volumetric fabrication)に向けられたシステムおよび方法に関する。
ターゲットの3D部分ジオメトリと、計算された投影との間の関係を理解するために、図1Aならびに図1B-1Dの座標系指定を考慮する。以下の議論に関して、グローバルデカルト座標系(x、y、z)を採用して、3Dビルド体積と、考慮される投影の角度θに向きが依存する回転されたデカルト座標系(x’、y’、z’)とを参照することが便利である。これらの座標系では、zは、体積10のまわりの角度θでの曝露の方位角的アレイ化のための軸である。各角度θに関して、投影が計算される。特定の角度θで、ターゲット体積内で生成される3次元強度マップIθ(x、y、z)を完全に決定する2次元関数Pθ(y’、z)として、投影を定義する(Pθは角度θに依存するが、2つの空間的次元を有するので、2次元関数と呼ばれることに留意すべきである)。最も単純なケースでは、投影は、樹脂体積をx’方向に伝播する(y’、z)ドメインの2次元イメージと考えられ得る場合がある。この理想的なケースでは、投影によって生成された3D強度プロファイルは、x’方向にターゲット体積を通して押し出された(y’、z)ドメインイメージのように見える。この近似は、照明投影がコリメートされる場合、物理的に良好に有効である。医療イメージング用途では、これは、平行ビーム断層撮影に類似する。本開示に関して、これは、光学的構成が長い焦点深度(特に、現在のSLM技術で利用可能な小さな回折角に関連する)を有するときはいつでも、十分に良好な近似である。一般的なケースでは、光の伝搬および減衰モデルは、特定の角度で2D投影関数から生成される3D強度マップを表す。この説明と図1Aでは、本方法の説明を簡単にするために理想的なケースを考慮する。
Claims (25)
- 3次元(3D)物体を形成する方法であって、
光学的に透明な樹脂コンテナ内に収容される光応答性樹脂の体積を提供することと、
光応答性樹脂の体積を通して複数の角度θで光学サブシステムからの光学投影を同時に方向付けることであって、光学投影が光応答性樹脂の体積を通って延びるz軸まわりに更に方向付けられる、方向付けることと、
光応答性樹脂の体積の選択された部分の硬化または除去の少なくとも一方を行って、他の部分を未変更のままにするのに十分である固定された時間的な曝露期間にわたって作用する計算された3次元強度分布を光学投影の個々に提供して、所望の3D部品を形成することと
を含む、方法。 - 複数の角度θで光学サブシステムからの光学投影を同時に方向付ける動作が、3D強度関数を空間内に生成する光学投影の同時の重ね合わせを含む、請求項1に記載の方法。
- 複数の角度θで光学サブシステムから送達される光学投影の計算設計が、
z軸を通って延びる複数のz平面の各1つについて、各角度θでの特定のz平面に対する1次元(1D)強度パターンを生成することと、
各z平面について特定の角度θに対する1D強度パターンを、その角度θからの2次元(2D)イメージ投影に組み立てて、これを各角度θについて行うこととを含む、請求項1に記載の方法。 - 複数の角度θで光学サブシステムから送達される光学投影の計算設計が、
フィルタ補正逆投影法(FBP)技術または反復最適化ベース技術の少なくとも一方を含むフーリエドメインメソッドを使用することを含む、請求項1に記載の方法。 - 固定された時間的な曝露期間の後に、樹脂コンテナをリンスして、光硬化された3D部品の領域から未硬化樹脂を除去することを更に含む、請求項1に記載の方法。
- 複数の角度θで光学サブシステムからの光学投影を同時に方向付ける動作が、複数の有機発光ダイオード(OLED)およびターゲット樹脂体積の周囲まわりに配設されたマイクロレンズアレイからの光学投影を生成することを含み、特定の角度θからの各投影が、特定のサブセットのOLEDから生成される、請求項1に記載の方法。
- 制御装置を使用して、OLEDアレイを制御すことを更に含む、請求項6に記載の方法。
- 3次元(3D)物体を形成する方法であって、
光学的に透明な樹脂コンテナ内に収容される光硬化性樹脂の体積と、光硬化性樹脂の体積を通って延びるz軸と、z軸に垂直に延びるx’軸とを提供することと、
z軸まわりに光学的に透明な樹脂コンテナを回転させ、同時に、樹脂体積が回転するにつれて樹脂体積座標系(x、y、z)に対して異なった角度θに沿って樹脂コンテナで連順次的な様式で静止光学サブシステムから固定されたx’方向に光学投影を方向付けることとを含み、
光学投影の2次元(2D)投影関数が、制御された3D曝露線量を送達するために、各角度θで制御され、
他方、樹脂体積に合計3D曝露線量を作り出す複数の角度θからの投影を含む、固定された時間的な曝露期間にわたって、合計3D曝露線量が、光硬化を所望の領域に生じさせるのに十分であり不所望の領域には生じさせない、方法。 - 光学的に透明な樹脂コンテナを、樹脂の屈折率に適合する屈折率を有する流体で満たされている第2のコンテナ内に、配置することを更に含む、請求項8に記載の方法。
- 光学的に透明なコンテナを回転させることが、光学的に透明なコンテナを回転ステージに固定することと、回転状態を使用して、光学的に透明なコンテナを回転させることとを含む、請求項8に記載の方法。
- 光学的に透明なコンテナの回転が、制御装置によって光学投影と同期される、請求項8に記載の方法。
- 静止光学サブシステムから光学投影を方向付けることが、静止デジタル光処理(DLP)プロジェクタから光学投影を方向付けることを含む、請求項8に記載の方法。
- 静止光学サブシステムから光学投影を方向付けることが、衝突光源の振幅または位相あるいは双方を制御する空間光変調器(SLM)を用いて光学投影を生成することを含む、請求項8に記載の方法。
- 固定された時間的な曝露期間の後に、樹脂コンテナをリンスして、光硬化された3D部品の領域から未硬化樹脂を除去することを更に含む、請求項8に記載の方法。
- 複数の角度θで光学サブシステムから送達される光学投影の計算設計が、
z軸を通って延びる複数のz平面の各1つについて、各角度θでの特定のz平面に対する1次元(1D)強度パターンを生成することと、
各z平面について特定の角度θに対する1D強度パターンを、その角度θからの2次元(2D)イメージ投影に組み立てて、各角度θについて生成する動作および組み立てる動作を行うことと
を含む、請求項8に記載の方法。 - 複数の角度θで光学サブシステムから送達される光学投影の計算設計が、
フィルタ補正逆投影法(FBP)技術または反復最適化ベース技術あるいは双方を含むフーリエドメインメソッドを使用することを含む、請求項8に記載の方法。 - 3次元(3D)物体を形成する方法であって、
光学的に透明な樹脂コンテナ内に収容される光硬化性樹脂の体積と、光硬化性樹脂の体積を通って延びるz軸と、z軸に垂直に延びるx’軸とを提供することと、
光学サブシステムを使用して、光学2次元(2D)投影を生成することと、
光硬化性樹脂の体積を通して方向付けられた光学2D投影を維持しながら、2D投影または樹脂コンテナの少なくとも一方を他方に対して回転させて、光硬化性樹脂の体積の完全な周囲のまわりに光学2D投影を受けることとを含み、
2D投影の2次元(2D)投影関数が、各角度θで制御されて、固定された時間的な曝露期間にわたって制御された3D曝露線量を送達し、複数の2D投影が、複数の角度θから生成され、複数の2D投影が合計されて、不所望の領域に光硬化を生じさせるのに不十分でありながら所望の領域に光硬化を生じさせるのに十分である3D曝露線量を樹脂体積に作り出す、方法。 - 2D投影または樹脂コンテナの少なくとも一方を他方に対して移動させることが、樹脂コンテナおよび光学サブシステムの双方が静止状態に保持されている間、光学2D投影を光硬化性樹脂の体積の方に方向付けるように構成された複数のミラーを有する回転アーム組立体を使用することを含む、請求項17に記載の方法。
- 2D投影または樹脂コンテナの少なくとも一方を他方に対して移動させることが、樹脂コンテナも回転している間、光学2D投影を光硬化性樹脂の体積の方に方向付けるように構成された複数のミラーを有する回転アーム組立体を使用することを含む、請求項17に記載の方法。
- 回転アーム組立体を使用することが、静止ミラーから光学2D投影を受ける回転アーム組立体を使用することを含む、請求項17に記載の方法。
- 光学サブシステムから2D投影を方向付けることが、静止デジタル光処理(DLP)プロジェクタから光学2D投影を方向付けることを含む、請求項17に記載の方法。
- 光学サブシステムから光学2D投影を方向付けることが、衝突光源の振幅または位相あるいは双方を制御する空間光変調器(SLM)を使用して静止光学サブシステムから光学2D投影を方向付けることを含む、請求項17に記載の方法。
- 樹脂コンテナを第2のコンテナ内に配置することを更に含み、第2のコンテナが、樹脂に適合された屈折率を有する流体を収容する、請求項17に記載の方法。
- 2D投影または樹脂コンテナの少なくとも一方を他方に対して移動させることが、樹脂コンテナが静止状態に保持されている間、樹脂コンテナのまわりを周方向に光学サブシステムを回転させて、光学2D投影を複数の角度から光硬化性樹脂の体積の方に方向付けることを含む、請求項17に記載の方法。
- 複数の角度θで光学サブシステムから送達される光学2D投影の計算設計が、
z軸を通って延びる複数のz平面の各1つについて、各角度θでの特定のz平面に対する1次元(1D)強度パターンを生成することと、
各z平面について特定の角度θに対する1D強度パターンを、特定の角度θからの2次元(2D)イメージ投影に組み立てること、ならびに、各角度θについて生成する動作および組み立てる動作を繰り返すことと
を含む、請求項17に記載の方法。
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US20200101673A1 (en) | 2020-04-02 |
AU2018266447B2 (en) | 2023-05-25 |
US11370173B2 (en) | 2022-06-28 |
WO2018208378A3 (en) | 2018-12-13 |
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