Development of a variable tensioning system to reduce separation force in large scale stereolithography

Song, Hongtao; Rodriguez, Nicholas A.; Seepersad, Carolyn Conner; Crawford, Richard H.; Chen, Morgan; Duoss, Eric B.

doi:10.1016/j.addma.2020.101816

Development of a variable tensioning system to reduce separation force in large scale stereolithography

Journal Article · Tue Dec 29 23:00:00 EST 2020 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2020.101816· OSTI ID:1870563

Song, Hongtao ^[1]; Rodriguez, Nicholas A. ^[1]; Seepersad, Carolyn Conner ^[1]; Crawford, Richard H. ^[1]; Chen, Morgan ^[1]; Duoss, Eric B. ^[2]

Univ. of Texas, Austin, TX (United States)
Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)

Projection micro stereolithography (PµSL) is an additive manufacturing tool that offers multiple advantages, including unparalleled resolution and throughput, but the ability to print high viscosity resin for large-scale parts is limited. One of the key challenges in PµSL is to separate a newly polymerized layer from the vat floor without damaging the part. Since the separation force scales with the printing area, the risk of damaging the part increases significantly with larger-scale systems and must be addressed. In this paper, a novel roll-to-roll, variable tensioning system is proposed to reduce the separation force during printing. A mathematical model is proposed to predict the separation force for different 2D geometries, and a set of experiments is conducted on an experimental prototype to validate the model. Finally, the effects of different separation parameters including peel rate and peel angle are discussed in detail. The results show that the proposed tensioning system reduces the separation force significantly.

View Accepted Manuscript (DOE)

Research Organization:: Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)

Sponsoring Organization:: USDOE National Nuclear Security Administration (NNSA)

Grant/Contract Number:: AC52-07NA27344

OSTI ID:: 1870563

Alternate ID(s):: OSTI ID: 1972397

Report Number(s):: LLNL-JRNL-812305; 1019621

Journal Information:: Additive Manufacturing, Journal Name: Additive Manufacturing Journal Issue: N/A Vol. 38; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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