Volumetric 3D-Printing of Endoskeletal Soft Robots with IN-VISION’s real 4K UV Projector PHOENIX
Cameron Darkes-Burkey (Department of Materials Science and Engineering) and Robert F. Shepherd (Department of Mechanical and Aerospace Engineering) from Cornell University worked on volumetric 3D printing of endoskeletal soft robots with IN-VISION’S Phoenix 4K Light Engine. The publication was recently published in Advanced Materials Journal.
Revolutionary 3D printing technology with IN-VISION'S Light Engine: The approaching era of computed axial lithography (CAL)-based complex on-demand manufacturing
Imagine creating complex 3D parts in one seamless step, bypassing the traditional layer-by-layer method. Computed Axial Lithography (CAL) is an innovative technology that is transforming the manufacturing industry. By circumventing the traditional layering approach, CAL enables the production of intricate structures in a single process. Overprinting, which allows for the formation of 3D geometries around prepositioned inserts, compensates for light occlusion through various angular projections. This innovation is set to transform additive manufacturing, especially in multi-material systems like endoskeletal robots.
Understanding CAL
The pioneering volumetric additive manufacturing method CAL (Computed Axial Lithography) is a breakthrough technique that constructs 3D objects in one go by exposing a rotating volume of photopolymer to a series of continuous angular projections. This method eliminates many drawbacks of the traditional additive manufacturing process such as the need for a layer-by-layer approach. CAL excels in printing high-viscosity or gelled resins and structures without support, delivering smooth surface finishes and achieving high throughput—approximately 100 times faster than alternative methods.
The custom-built CAL setup with Phoenix 4K Light Engine
To achieve this overprinting, a custom-built CAL setup was necessary. The printer's main components include a 4k light engine, projecting 405 nm light through a condenser lens, which collimates the emitting light. This light then enters a borosilicate glass cube containing water where its optical index matches the suspended vial of hydrogel resin. Detailed information on how the construction works is available in the Supporting Information.
New possibilities with CAL
Using CAL for overprinting will open the door for many capabilities for multi-material manufacturing, paving the way for endoskeletal soft robots. Endoskeletons in soft robots enable targeted actuation while minimizing unwanted deflections and twists. CAL enhances the economic and temporal efficiency of this process, allowing for the rapid 3D printing of customized soft materials around inserts within minutes.
In conclusion, Computed Axial Lithography (CAL) is poised to revolutionize additive manufacturing, particularly in the realm of complex, multi-material systems. The future of manufacturing is here, and CAL is leading the charge.
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