Development of a 3D printer using scanning projection stereolithography

TLDR

Maskless lithography using a digital micromirror device (DMD) projects patterns with up to 10 µm resolution onto photoresist. The authors developed a rapid, low‑cost 3D fabrication system capable of producing micro‑scale features in centimeter‑scale objects. The system stitches projected images over a 5 cm² area and uses a z‑stage to stack layers, eliminating developing or etching steps while enabling robust, scalable 3D devices. The system successfully printed micro‑scale objects and a functional microfluidic droplet device, with integrity confirmed by dye flow through the channels.

Abstract

Abstract We have developed a system for the rapid fabrication of low cost 3D devices and systems in the laboratory with micro-scale features yet cm-scale objects. Our system is inspired by maskless lithography, where a digital micromirror device (DMD) is used to project patterns with resolution up to 10 µm onto a layer of photoresist. Large area objects can be fabricated by stitching projected images over a 5cm 2 area. The addition of a z-stage allows multiple layers to be stacked to create 3D objects, removing the need for any developing or etching steps but at the same time leading to true 3D devices which are robust, configurable and scalable. We demonstrate the applications of the system by printing a range of micro-scale objects as well as a fully functioning microfluidic droplet device and test its integrity by pumping dye through the channels.