Single micron resolution mass-produced parts

Nanofabrica recently announced the commercial launch of the world’s first mass production additive manufacturing (AM) platform aimed at micro manufacturing applications.  

With single micron resolution, Nanofabrica’s technology is targeted  squarely at the optics, semi-conductor, micro-electronics, MEMS, microfluidics, and life sciences sectors.

These sectors exhibit high-level demand for accuracy and complexity, and until now the only route to market has been through disproportionately expensive or restrictive traditional manufacturing technologies.

The key to the success of the Nanofabrica technology is that it brings the benefits of AM to micro manufacturers for the first time, including hitherto impossible part complexity (enhancing design and functionality), no tooling costs, minimal set up costs, and the ability to mass customise and personalise products. 

As a versatile technology appropriate for prototyping, small batches, and mass manufacturing, the technology is now stimulating innovation in the micro manufacturing sector.

The Nanofabrica AM platform achieves true single micron resolution mass-produced parts across numerous sectors as a result of a range of technological innovations.

Hardware

Hardware-wise, the AM platform uses the well-known digital light processor (DLP) engine, but crucially this is used in conjunction with adaptive optics.

In the Nanofabrica AM platform, once the image is projected through the DLP unit, the light then passes through an adaptive optics module which electronically controls various critical optical working point parameters such as focus, tilt, and astigmatism. 

The DLP unit is also placed on an optomechanical apparatus which facilitates real time corrections of other working parameters, mainly location and accuracy in the XY plane. This apparatus also corrects for degrees of freedom such as wobbling to allow for better surface finish on parts. 

The Nanofabrica AM technology is able to build small parts and also large ‘macro’ parts with intricate micro details, which can be manufactured at speed through what is called a ‘multi-resolution’ strategy. This means that the areas where fine details are required are printed relatively slowly, but in the areas where the details aren’t so exacting, the part is printed at a speeds 10-100 times faster. This makes the entire printing speed anything from 5-100 times faster than other micro AM platforms. 

Software 

Another key enabling technology behind the Nanofabrica micro AM platform are the algorithms used to control and optimise the hardware during production.  

Within the AM platform, feedback algorithms are used in a closed loop to increase accuracy and repeatability in production. Of particular importance, positioning errors are corrected using laser distance measurements. 

Another algorithm family is focussed on customised file preparation, optimizing print angle, build plate orientation, and supports, etc, all to ensure the most accurate, timely, and cost-effective part production.

Materials 

Another major breakthrough is in the area of materials. Through rigorous R&D, and using considerable in-house materials expertise, Nanofabrica has managed to develop its own proprietary materials (based on the most commonly used industry polymers such as ABS and PP) which enable ultra high-resolution in parts built through modifications in polymerisation radii, viscosity, surface tension, and spectral-optical penetration depth.

Through the combination of hardware, software, and material innovations, Nanofabrica’s micro AM technology is commercially available to be applied to even the most exacting micro manufacturing applications across industry.