A pixel based solidification model for projection based stereolithography technology

Projection-based stereolithography (pSL) is a powerful technique for fabricating three-dimensional (3-D) freeform structures. This study developed a new pixel-based solidification model for pSL to predict the patterning results. pSL technology makes it possible to create a two-dimensional (2-D) pattern in a single exposure, using a dynamic mask capable of generating 2-D images with micro-resolution. Then, a 3-D structure can be fabricated by stacking the 2-D patterns. Therefore, pixel-based modeling is crucial for predicting the patterning results because the pixel is the fundamental component of the illuminated 2-D images in the patterning process. This study constructed a mathematical model to describe the intensity distribution of an illuminated image. The model was used to predict solidified shapes by calculating the exposure energy and compared with patterning results. The findings showed that our model is quite useful for estimating fabrication results obtained using pSL technology.