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Dithering method for improving the surface quality of a microstructure in projection microstereolithography

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Abstract

In layered manufacturing, geometrical gap occurs between the computer-aided design (CAD) model and the fabricated, due to the stair-stepping effect. It will deteriorate the surface quality of the microstructure. By reducing the stair steps, the surface quality of a layered manufactured microstructure can be improved. In this research, dithering method is introduced to improve the surface quality of a microstructure in projection microstereolithography. The dithering method can represent grayscale effect with monochrome image, so it is applicable to the digital micromirror device for ultraviolet, which allows monochrome image as an input format. By adjusting the beam intensity using the dithered image, it is possible to control the cure depth of the resin within a layer. In a cross-section, the region to be dithered is obtained by the difference of the cross-sections between the current layer and the previous layer. It is called a compensation area (CA) in this research. The gray level to be applied is determined considering the CAD model and the curing characteristics of the resin. The dithered CA is then combined with the current cross-section. The parabola-shaped microstructures, using dithered and non-dithered cross-sectional images, have been fabricated and compared. The dithering method has shown good performance for improving surface quality and reducing the fabrication time.

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Authors and Affiliations

  1. Pusan National University, Busan, South Korea

    In Baek Park, Young Myoung Ha & Seok Hee Lee

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  1. In Baek Park
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  2. Young Myoung Ha
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  3. Seok Hee Lee
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Correspondence to Seok Hee Lee.

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Park, I.B., Ha, Y.M. & Lee, S.H. Dithering method for improving the surface quality of a microstructure in projection microstereolithography. Int J Adv Manuf Technol 52, 545–553 (2011). https://doi.org/10.1007/s00170-010-2748-6

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  • DOI: https://doi.org/10.1007/s00170-010-2748-6

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