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<p>This study presents a comprehensive theoretical and experimental investigation of vat photopolymerization using ultraviolet pulsed laser irradiation (VPP-UV-PL). A process model is developed by extending Jacob’s working curve, originally formulated for CW sources, to pulsed Gaussian beam regimes. The model incorporates both spatial and temporal pulse overlap, enabling prediction of cured geometries by accounting for cumulative exposure from successive laser pulses along and between scan lines. Closed-form expressions are derived for the full 2D curing profile as well as the curing depth (<i>C</i><sub><i>d</i></sub>) and width (<i>C</i><sub><i>w</i></sub>) of individual scan lines. Simulations and experiments, performed with identical parameters demonstrate excellent agreement at low average exposure, with minor deviations at higher exposures attributed to scattering and unmodeled chemical effects. Numerical simulations reveal a clear morphological transition from isolated hillocks to sawtooth-like strings and ultimately to ribbon-like structures as the average power increases at a fixed scanning speed, or equivalently, as the scanning speed decreases at a fixed average power. These simulation results were experimentally validated by fabricating surface structures over a wide range of scanning speeds and average powers using a custom-built three-dimensional stereolithography (SLA) printer. Ribbon-like structures were formed at a high scanning speed of 100&#xa0;mm/s for exposure doses exceeding 60&#xa0;mJ/cm<sup>2</sup>, whereas isolated hillocks were obtained for exposure doses below 7&#xa0;mJ/cm<sup>2</sup>. Increasing the scanning speed reduces pulse overlap, leading to the formation of discrete features. At very high scanning speeds of 200&#xa0;mm/s, the morphology reverted to isolated hillocks even for exposure doses as high as 90&#xa0;mJ/cm<sup>2</sup>. Beyond achieving uniform structures, the method enables controlled fabrication of periodic surface textures (&lt; 100 µm features) with potential applications in cell growth guidance, wettability control, and optical surface functionalization. This model offers a predictive tool for optimizing high-resolution, high-speed additive manufacturing with pulsed UV lasers.</p>

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Process modeling and experimental validation of curing profiles in pulsed UV laser stereolithography

  • 期刊论文

  • 发表日期：

    2026年6月25日

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  • Aliasghar Ajami,
  • Soodabeh Moniri

摘要

This study presents a comprehensive theoretical and experimental investigation of vat photopolymerization using ultraviolet pulsed laser irradiation (VPP-UV-PL). A process model is developed by extending Jacob’s working curve, originally formulated for CW sources, to pulsed Gaussian beam regimes. The model incorporates both spatial and temporal pulse overlap, enabling prediction of cured geometries by accounting for cumulative exposure from successive laser pulses along and between scan lines. Closed-form expressions are derived for the full 2D curing profile as well as the curing depth (Cd) and width (Cw) of individual scan lines. Simulations and experiments, performed with identical parameters demonstrate excellent agreement at low average exposure, with minor deviations at higher exposures attributed to scattering and unmodeled chemical effects. Numerical simulations reveal a clear morphological transition from isolated hillocks to sawtooth-like strings and ultimately to ribbon-like structures as the average power increases at a fixed scanning speed, or equivalently, as the scanning speed decreases at a fixed average power. These simulation results were experimentally validated by fabricating surface structures over a wide range of scanning speeds and average powers using a custom-built three-dimensional stereolithography (SLA) printer. Ribbon-like structures were formed at a high scanning speed of 100 mm/s for exposure doses exceeding 60 mJ/cm2, whereas isolated hillocks were obtained for exposure doses below 7 mJ/cm2. Increasing the scanning speed reduces pulse overlap, leading to the formation of discrete features. At very high scanning speeds of 200 mm/s, the morphology reverted to isolated hillocks even for exposure doses as high as 90 mJ/cm2. Beyond achieving uniform structures, the method enables controlled fabrication of periodic surface textures (< 100 µm features) with potential applications in cell growth guidance, wettability control, and optical surface functionalization. This model offers a predictive tool for optimizing high-resolution, high-speed additive manufacturing with pulsed UV lasers.