High Light-Efficiency Holographic Tomographic Volumetric Additive Manufacturing using a MEMS-based Phase-only Light Modulator

Abstract

Light-based 3D printing, which relies on photocurable resins, has shown the capability to produce complex geometries with high resolution and fidelity. Tomographic Volumetric Additive Manufacturing (TVAM) employs a digital micromirror device (DMD) to project high-speed sequences of amplitude light patterns into a rotating resin volume, enabling rapid fabrication of 3D structures through photopolymerization. Typically, the light projection efficiency in such binary amplitude modulator-based systems is below a few percent. Recent advancements introduced phase encoding in TVAM using binary amplitude modulators, improving depth control and boosting light projection efficiency to approximately 10%. This was achieved by implementing the Lee hologram technique to encode phase into binary amplitude patterns. In this work, we present the first 3D printing platform utilizing a phase-only light modulator (PLM), based on an array of micro-electro-mechanical pistons. Compared to amplitude encoding, phase encoding with the PLM yields a 70-fold increase in laser power efficiency. By coupling this efficient light engine with a speckle reduction method in holographic volumetric additive manufacturing (HoloVAM), we experimentally demonstrate printing across different scales from hundreds of micrometers to centimeters using only digital control. The PLM opens up new avenues in volumetric AM for holographic techniques using low-cost single-mode UV laser diodes.