Additive Manufacturing Letters

Vat photopolymerization additive manufacturing process modeling: a thermal-chemical coupling approach informed by in-situ and ex-situ characterization data

At a glance

I presents a new way to model vat photopolymerization (VPP) using in-situ infrared temperature data to solve an inverse heat conduction problem (IHCP) to optimize for thermal-chemical reaction parameters.

Abstract

Vat photopolymerization (VPP) is one of the most widely used additive manufacturing methods. The VPP process temperature and material curing reaction interplay with each other to critically determine the final product quality. Insights about the time-varying process temperature and degree of conversion (DoC) is desired for VPP process control but difficult to attain due to lacking effective operando characterization technologies. This work reports a new method to create a thermal-chemical model of the VPP process by solving an inverse heat conduction problem (IHCP) based on in-situ observable temperature measurement to estimate the chemistry reaction-induced heat source that is a function of DoC. Ex-situ photo differential scanning calorimetry (Photo-DSC) characterization is used to optimize the chemistry reaction model parameters so that DoC can be calculated. Specifically, vat substrate temperature is measured using an in-situ infrared thermal camera and used as input to solve an IHCP for estimating exothermic heat generation rate for the internal heat generation component at the curing part.Overall, the newly developed VPP modeling framework combines an IHCP that is informed by in-situ thermal monitoring with a chemical reaction heat generation and conduction model that isoptimized by using Photo-DSC characterization data. The model prediction of DoC is experimentally validated by comparing against ex-situ spectroscopy measurements of printed parts at different exposure times.

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Open-Architecture Two-Wavelength Vat Photopolymerization

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In-situ thermal monitoring informed modeling of VPP