A new 3D printing method called blurred tomography has been developed by Canadian researchers to rapidly produce microlenses with commercial-level optical quality. This new method, which involves adding optical blurring to the beams of light used for the printing process, allows for the production of optically smooth surfaces. The researchers have demonstrated the effectiveness of this method by creating a millimeter-sized plano-convex optical lens with imaging performance comparable to a glass lens available on the market. The method is also capable of producing optical components that are ready to use in just 30 minutes, making it faster and more efficient than traditional manufacturing methods.
The researchers believe that this new method could be valuable for cost-effective and swift prototyping of optical components due to the affordability of the tomographic 3D printer and the materials used. The freeform nature of tomographic 3D printing could also simplify optical designs by replacing multiple standard optics with printed optics that have complex shapes. This could have applications in a wide range of industries, from commercial manufacturers to garage-based inventors, as it allows for quick prototyping of new optical devices.
Tomographic volumetric additive manufacturing is a relatively new approach that uses projected light to solidify a light-sensitive resin in specific areas, allowing an entire part to be printed at once without support structures. Existing tomographic methods are not able to directly print imaging-quality lenses due to the striations caused by the pencil-like beams used, resulting in small ridges on the component’s surface. Post-processing steps can be used to create smooth surfaces, but this adds time and complexity, which takes away the rapid prototyping advantage of tomographic printing.
The researchers have tested the blurred tomography method by creating a simple plano-convex lens with imaging resolution comparable to a glass lens. They have also demonstrated the production of a 3×3 array of microlenses using the new method, showing that it is possible to image a business card with the array printed with blurred tomography but not with conventional tomographic 3D printing. They are now working to improve the accuracy of optical components by optimizing the light patterning method and incorporating material parameters into the printing process.
The researchers are also focused on introducing automation of the printing process to make the system robust enough for commercial use. They believe that tomographic 3D printing is a rapidly maturing field with applications in various industries, and the new blurred tomography method adds a rapid and low-cost alternative for the fabrication of millimeter-sized optical components. This new technology has the potential to have a significant impact on future technologies by providing a faster and more efficient method for prototyping new optical devices.
