Vat Photopolymerization Processes

Cubital’s Solid Ground Curing (SGC)/ Mask Projection VP process
• SGC systems were developed by Cubital Ltd. Cubital was found in

1987 as an internal R&D unit at Seitex Corporation Ltd, and first SGC
system was installed in 1991
• The SGC machine analyzes a CAD file and renders the object as a
stack of "slices". The image of the working slice is "printed" on a
glass photo-mask using an electro-static process similar to laser
printing. That part of the "slice" representing solid material remains
transparent.
Principle
Principle
• Parts are built, layer by layer, from a liquid photopolymer resin that
solidifies when exposed to UV light.
• Multiple parts may be processed and built in parallel by grouping them
into batches (runs) using Cubital’s proprietary software.
• Each layer of a multiple layer run contains cross-sectional slices of one
or many parts.
• The process is self-supporting and does not require the addition of
external support structures to emerging parts since continuous structural
support for the parts is provided by the use of wax, acting as a solid
support material.
Mask Generation
Advantages
• Multiple parts can be positioned within the entire working envelop

resulting high throughput
• No support structure is required as the wax support the structure in
all directions
• Each layer is fully cured resulting that the dimension is very stable
with no shrinkage effect after the process and requires no post-
curing process
• Capable to build even the most complicated parts without much
difficulty
• Build session can be interrupted and erroneous layer can be erased
Disadvantages
• The process is rather complicated which required skilled people to

look after and unattended operation is not possible
• The resin consumption is disregard of the size of the cross section of
the parts but only depended on the number of layers resulting that it
is too expensive for parts with small cross sectional area
• High equipment cost (over US$500,000) made it not easily to be
justified
Applications
• General applications: Conceptual design presentation, design proofing,
engineering testing, functional analysis, exhibitions and pre-production
sales, market research.
• Tooling and casting applications: Investment casting, sand casting, and
rapid, tool-free manufacturing
• Mold and tooling: Silicon rubber tooling, epoxy tooling, spray metal
tooling, acrylic tooling, and plaster mold casting.
• Medical imaging: Diagnostic, surgical, operation and reconstruction
planning and custom prosthesis design.
SOLID OBJECT ULTRAVIOLET-LASER PRINTER
Principle
• The SOUP system is based on the laser lithography technology.
• The SOUP system has the option for XY plotter, which is easier to
control and has less optic problems than the galvanometer mirror
system.
• The main trade-off is in scanning speed and the building speed.
• Parameters which influence performance and functionality are
galvanometer mirror precision for the galvanometer mirror machine,
laser spot diameter, slicing thickness and resin properties.
Schematic of SOUP® system (Adapted from CMET brochure)
Process
The SOUP process contains the following three main steps:
1. Creating a 3D model with a CAD system: The 3D model of the part is
created with a commercial CAD system.
2. Processing the data with the SOUPware: Using SOUPware, can edit
CAD data, repair its defects, like gaps, overlaps, etc., slice the model into
cross-sections and finally, SOUP ware generates the SOUP machine
data.
3. Making the model with the SOUP units: The laser scans the resin,
solidifying it according to the cross-sectional data from SOUPware. The
elevator lowers and the liquid covers the top layer of the part which is
recoated and prepared for the next layer.
4. This is repeated until the whole part is created.
• The galvanometer mirror type uses an ultra-high speed scan for raster
scanning with a galvanometer mirror, creating a part in a very short time,
with scanning speeds of up to 20 m/s
• These types of SOUP machines can make the laser beam diameter very
small (smallest, 0.1 mm) for creating an extremely small model with high
precision.
The main advantages of SOUP systems are:

(1) New recoating system. The new recoating system provides a more
accurate Z layer and shorter production time.
(2) Software system. The software system allows for real time processing.
(3) High scanning speed. It has scanning speeds of up to 20 m/sec.
The main disadvantages of SOUP systems are:
(1) Requires support structures. Structures that have overhangs and
undercuts must have supports that are designed and fabricated together
with the main structure.
(2) Requires post-processing. Post-processing includes removal of supports
and other unwanted materials, which is tedious, time consuming and can
damage the model.
(3) Requires post-curing. Post-curing may be needed to cure the object
completely and ensure the integrity of the structure.
Applications
• Concept models
• Working models for form fitting and simple functional tests.
• Master models and patterns for silicon molding, lost-wax, investment
casting, and sand casting.
• Medical purposes: Creating close to exact physical models of a
patient’s anatomy from CT and MRI scans.
Two-Photon Vat Photopolymerisation
• 2P- VP was first invented in 1970s.
• In 2P-VP, two lasers were used to irradiate points

in a vat of photopolymer.
• The photoinitiator requires two photons to strike it
before it decomposes to form a free radical that can
initiate polymerization.
• The effect of this two-photon is to increase the
resolution of photopolymerisation process.
• Only near the center of the laser is the irradiance
high enough to provide the photon density
necessary to ensure that two photons will strike the
same photoinitiator molecule.
• Feature sizes of 0.2 micron or smaller have been

achieved using 2P-VP process.
Two-Photon Vat Photopolymerisation
• Direct fabrication of arbitrary 3D microstructures- 2P-VP is based on

non-linear interaction of focused laser pulses with photosensitive resin, it
can be used to initialize the polymerization process anywhere in the
volume and hence allows for the direct fabrication of arbitrary 3D micro-
structures.
• Good Structural resolution and quality

Disadvantages
• Lack of scalability- lack of scalability makes it premature for the fabrication

of large-scale architected structural materials.
• Negative effects accompanied by high resolution- To achieve maximum

resolution, the energy input needs to be small. However, when the input
energy is close to minimum threshold, the correlation between voxel size,
laser intensity and printing speed become highly non-linear, which produces
fluctuations easily.
Applications
• Photonics- fabrication of micro-optical component and devices such as
micro-prism arrays diffractive optical elements.
• Biological application- Tissue engineering, drug delivery, scaffold and

medical implants.
• Microneedles- used for drug delivery devices
Bull model fabricated by 2p-VP. The size scale bar is 1 μm

Vat Photopolymerization Processes

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Cubital’s Solid Ground Curing (SGC)/ Mask Projection VP process

• SGC systems were developed by Cubital Ltd. Cubital was found in

• Multiple parts can be positioned within the entire working envelop

• The process is rather complicated which required skilled people to

The main advantages of SOUP systems are:

• 2P- VP was first invented in 1970s.

• In 2P-VP, two lasers were used to irradiate points

• Feature sizes of 0.2 micron or smaller have been

• Direct fabrication of arbitrary 3D microstructures- 2P-VP is based on

• Good Structural resolution and quality

• Lack of scalability- lack of scalability makes it premature for the fabrication

• Negative effects accompanied by high resolution- To achieve maximum

• Biological application- Tissue engineering, drug delivery, scaffold and

• Microneedles- used for drug delivery devices

Bull model fabricated by 2p-VP. The size scale bar is 1 μm

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