In the rapidly evolving world of additive manufacturing, a groundbreaking technique developed by researchers at the Nanjing University of Science and Technology is set to revolutionize the production of precision lenses. This innovative method, known as time-dependent dynamic laser writing (DLW), promises to address longstanding challenges in dimensional accuracy and surface smoothness, opening new avenues for industries that rely on high-precision optics, including the energy sector.
At the heart of this development is Chengxue Piao, a leading researcher from the School of Mechanical Engineering at Nanjing University of Science and Technology. Piao and his team have tackled the inherent limitations of current vat photopolymerization-based additive manufacturing techniques, which often struggle with controlling the dimensional accuracy of printed components due to position-dependent features.
The DLW approach leverages material growth functions (MGFs) created by laser direct irradiation with controlled energy doses. By accumulating these MGFs along the scanning path, the DLW method generates surfaces with unparalleled precision and smoothness. “The stability of MGFs and the process homogenization make DLW less sensitive to process errors,” Piao explains. “This results in a naturally ultra-smooth surface, which is crucial for applications in precision optics.”
The implications for the energy sector are profound. Precision lenses are essential components in solar concentrators, laser systems for energy transmission, and advanced imaging technologies used in renewable energy research. The ability to produce lenses with minimal form errors and exceptional surface roughness can significantly enhance the efficiency and performance of these systems.
In a demonstration of the DLW technique, Piao’s team printed a millimeter-scale spherical lens in just 5.67 minutes. The resulting lens exhibited a three-dimensional form error of 0.135 micrometers (root mean square, RMS) and a surface roughness of 0.31 nanometers (RMS). These metrics represent a substantial improvement over current continuous layer-wise and volumetric printing methods, which typically achieve form errors an order of magnitude larger.
The versatility of the DLW method was further showcased through the successful printing of polymer lens arrays, freeform polymer lenses, and even fused silica lenses. These achievements highlight the potential of DLW to advance the state-of-the-art in 3D printing of precision lenses, offering a glimpse into a future where complex optical components can be manufactured with unprecedented accuracy and efficiency.
The research, published in the International Journal of Extreme Manufacturing, translates to “International Journal of Extreme Manufacturing” in English, underscores the transformative potential of DLW in various industrial applications. As the energy sector continues to push the boundaries of innovation, technologies like DLW will play a pivotal role in shaping the future of precision optics and additive manufacturing.
The energy sector is not the only beneficiary of this breakthrough. Industries ranging from aerospace to biomedical engineering stand to gain from the enhanced capabilities of DLW. The ability to produce high-precision optical components with greater efficiency and accuracy can drive advancements in fields as diverse as telecommunications, medical imaging, and scientific research.
As researchers and engineers continue to explore the full potential of DLW, the possibilities for innovation seem limitless. The work of Chengxue Piao and his team at Nanjing University of Science and Technology represents a significant step forward in the quest for precision and perfection in additive manufacturing. The future of 3D printing is bright, and DLW is poised to illuminate the path forward.
