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Proceedings Paper

DLP-based light engines for additive manufacturing of ceramic parts
Author(s): M. Hatzenbichler; M. Geppert; S. Gruber; E. Ipp; R. Almedal; J. Stampfl
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Paper Abstract

In the framework of the European research project PHOCAM ( the involved partners are developing systems and materials for lithography-based additive manufacturing technologies (AMT) which are used for shaping advanced ceramic materials. In this approach a ceramic-filled photosensitive resin is selectively exposed layer by layer. By stacking up the individual layers with a typical layer thickness between 25 and 50μm, a three-dimensional part is built up. After structuring, a solid part consisting of a ceramic filled polymer is obtained. The polymer is afterwards burnt off and in a last step the part is sintered to obtain a fully dense ceramic part. The developed systems are based on selective exposure with DLP projection (Digital Light Processing). A key element of the developed systems is a light engine which uses digital mirror devices (DMD) in combination light emitting diodes (460nm) as light source. In the current setup DMDs with 1920x1080 pixels are used. The use of LEDs in combination with a customized optical projection system ensures a spatial and temporal homogeneity of the intensity at the build platform which is significantly better than with traditionally used light engines. The system has a resolution of 40μm and a build size of 79x43x100mm. It could be shown that this system can fabricate dense ceramic parts with excellent strength. In the case of alumina densities up to 99.6% of the theoretical density were achieved, yielding a biaxial strength of 510MPa. Besides technical ceramics like alumina it is also possible to structure bioceramics, e.g. tricalcium phosphate.

Paper Details

Date Published: 13 February 2012
PDF: 10 pages
Proc. SPIE 8254, Emerging Digital Micromirror Device Based Systems and Applications IV, 82540E (13 February 2012); doi: 10.1117/12.907113
Show Author Affiliations
M. Hatzenbichler, Technische Univ. Wien (Austria)
M. Geppert, FOTEC Research and Technology Transfer GmbH (Austria)
S. Gruber, Technische Univ. Wien (Austria)
E. Ipp, IN-VISION Digital Imaging Optics GmbH (Austria)
R. Almedal, Visitech AS (Norway)
J. Stampfl, Technische Univ. Wien (Austria)

Published in SPIE Proceedings Vol. 8254:
Emerging Digital Micromirror Device Based Systems and Applications IV
Michael R. Douglass; Patrick I. Oden, Editor(s)

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