Recent developments in computation, materials formulation, and hardware design for computed axial lithography (Invited Paper)

The formation of three-dimensional objects through the tomographic reconstruction of a patterned light dose, also known as computed axial lithography (CAL), is enabled by careful co-optimization of the reactive material’s composition, the algorithm that computes the delivered light patterns, and the opto-mechanical system that delivers the light. To approach industrially relevant component sizes, spatial resolution, and dimensional accuracy, work is needed on all three of these technological pillars. Firstly, I will describe recent progress in formulating ceramic-photopolymer nanocomposites where careful selection of particle geometry, mixing protocol, and illumination wavelength offer a path towards CAL printing. Secondly, I will describe a first-principles approach to modeling the aggregate scattering behavior of such materials, based on Mie scattering theory, to aid in the computation of projected light patterns. Thirdly, I will explore some physical considerations for scaling up the printing volume of CAL systems. Finally, I will describe some ongoing work to expand the range of CAL-printable materials to those shaped by ring-opening metathesis polymerization.