Project: Advanced Algorithms for Computed Axial Lithography: Enabling True Volume-at-Once Additive Manufacturing
We have invented (with Livermore Lab), and are developing towards commercialization, a new approach to additive manufacturing: Computed Axial Lithography (CAL). Existing additive processes have serious speed and mechanical strength limitations that arise from the fact that they print laboriously, layer-by-layer. CAL, on the other hand, creates the entire volume of a design at once by rotating dynamically-evolving projected light pattern relative to a volume of photosensitive material. A 3D object emerges as hundreds of projections from different angles sum together to impart a customized illumination dose to the material.
As well as offering at least an order of magnitude faster printing, CAL eliminates the need for dedicated supporting structures, can print much smoother surfaces, and can work with a wider range of starting materials including very viscous resins as well as extremely soft, flexible and fragile materials. A further unique advantage is that of ‘overprinting’, which allows 3D designs to be fabricated around pre-existing solid objects made from other materials. We foresee CAL changing the way designs are prototyped but also driving additive manufacturing into scores of new applications.
Hayden Taylor is an assistant professor of Mechanical Engineering at Berkeley. His research group invents, models and simulates manufacturing processes, particularly those where process physics and geometrical design complexity interact strongly to determine manufacturing performance. CAL is one example of such a process; another particular focus has been on nanoscale manufacturing, including nanoimprint lithography, 2D materials exfoliation, and semiconductor wafer polishing and etching process flows. He holds a Ph.D. in EECS from MIT and a B.A. and M.Eng. from Cambridge University.