DLP列印之間隙控制探討

Abstract

在使用光固化技術進行具有微間隙結構的列印時，常常會遇到間隙消失的問題，這會影響成品的功能性，這種現象為光固化列印的尺寸效應。本研究主要從化學和光學兩方面來探討此問題。從化學角度來看，自由基在固化反應中扮演著關鍵角色，其積聚可能會加速樹酯的固化。而從光學角度來看，DLP投影系統的光源之像素亮度呈高斯分布，會導致光能量溢出。隨著列印設備解析度的提高，每單位面積的光能量增加，並且曝光圖案的光能量溢出會使間隙區域亮度增加，進而導致樹酯在預期外的區域固化。 本研究提出了多種解決方案以應對這些挑戰。在化學方面，這些解決方案包括加熱樹酯、增加曝光之間的間隔時間，以及添加能夠淬滅自由基的材料。在光學方面，則涉及調整灰階值和改變光能量分配方式。 最後，綜合所有的有利條件條件，確定了使用本研究的設備能夠達到的最小間隙尺寸，並將此應用於離子阱結構的列印中。

When using photopolymerization technology to print gap structures, issues often arise where the gaps disappear, compromising the functionality of the final product, which is the size effect in photopolymerization printing. This study primarily investigates this issue from both chemical and optical perspectives. Chemically, free radicals play a crucial role in the curing reaction, and their accumulation can accelerate resin curing. Optically, the light energy from the DLP source extends beyond the projection pattern due to the Gaussian distribution. As printer resolution improves, the light energy per unit area increases, and extended energy beyond the projection area can elevate brightness in gap areas, causing resin to cure unexpectedly. This study proposes several solutions to address these challenges. Chemically, solutions include heating the resin, increasing intervals between exposures, and adding materials that can quench free radicals. Optically, adjustments involve modifying grayscale values and altering light distribution methods. Ultimately, by optimizing these conditions, the study determines the minimum achievable gap size using the equipment employed, and applies this knowledge to printing ion trap structures.