Overprinting with Tomographic Volumetric Additive Manufacturing

TL;DR

This paper demonstrates advanced overprinting capabilities in tomographic volumetric additive manufacturing, enabling complex multi-material and embedded structure fabrication with optimized projection patterns in seconds.

Contribution

It introduces a differentiable ray optical optimization framework for TVAM, enhancing speed, flexibility, and quality in overprinting scenarios including biomedical, microfluidic, and embedded optical components.

Findings

Successful fabrication of microfluidic systems with embedded features

Rapid optimization of projection patterns within minutes

Enhanced overprinting versatility for complex geometries

Abstract

Tomographic Volumetric Additive Manufacturing (TVAM) is a light-based 3D printing technique capable of producing centimeter-scale objects within seconds. A key challenge lies in the calculation of projection patterns under non-standard conditions, such as the presence of occlusions and materials with diverse optical properties, including varying refractive indices or scattering surfaces. This work focuses on demonstrating a wide variety of overprinting scenarios. First, utilizing a telecentric laser-based TVAM (LaserTVAM), we demonstrate the printing of a microfluidic perfusion system with biocompatible resins on existing nozzles for potential biomedical applications. In a subsequent demonstration, embedded spheres within the bio-resins are localized inside this perfusion system, optimized into specific patterns, and successfully connected to the nozzles via printed channels in less than three minutes. As a final LaserTVAM example, we print gears on a glossy metal rod, taking into account the scattered rays from the rod's surface. Using a non-telecentric LED-based TVAM (LEDTVAM), we then overprint engravings onto an existing LED placed in the resin. With an additional printed lens on this LED, we can project those engravings onto a screen. In a similar application with the same setup, we print microlenses on a glass tube filled with water, allowing us to image samples embedded within the glass tubes. Based on a differentiable physically-based ray optical approach, we are able to optimize all these scenarios within our existing open-source framework called Dr.TVAM. This framework enables the optimization of high-quality projections for both LaserTVAM and LEDTVAM setups within minutes, as well as lower-quality projections within seconds, outperforming existing solutions in terms of speed, flexibility, and quality.