Three-Dimensional (3D) Printing Implemented by Computer-Generated Holograms for Generation of 3D Layered Images in Optical Near Field

Abstract

Photocurable three-dimensional (3D) printing is a stepwise layer-by-layer fabrication process widely used in the manufacture of highly specialized objects. Current 3D printing techniques are easily implemented; however, the build rate is slow and the surface quality is less than ideal. Holographic 3D display (3DHD) technology makes it possible to reform planar wavefronts into a 3D intensity distribution, which appears as a 3D image in space. This paper examined the application of holographic imaging technology to 3D printing based on photocurable polymers. The proposed system uses a 3DHD diffractive optics system based on a liquid-crystal-on-silicon spatial light modulator (LCoS-SLM), wherein a 3D layered image is created in the optical near field, based on a computer-generated hologram (CGH) optimized using the iterative angular spectrum algorithm (IASA) and a circular IASA. From a single CGH, multiple 2D sliced images are created in space to form a 3D optical image used to initiate the photopolymerization of photocurable resin to form 3D objects. In experiments, the proposed 3D printing system was used to create five polymer objects with a maximum axial length of 25 mm and minimum feature width of 149 μm. The phase-only CGH reformed the incident light into a distribution of optical intensity with high diffraction efficiency suitable for photocuring. Despite limitations pertaining to fabrication area and axial complexity in this initial study, the proposed method demonstrated high light efficiency, high resolution in the lateral direction, rapid fabrication, and good object continuity.