SYSTEM AND METHOD FOR ENHANCED STEREOLITHOGRAPHY 3D PRINTING

Abstract

A system for 3D printing utilizing non-UV, near-UV, and/or UV photons with or without engineered angular momentum, which may be organized as shaped flux or flux shaping structures of non-UV photons, near-UV photons, and/or UV photons, the system comprising: one or more of a coherent source, a partially-coherent source, and an incoherent source of one or more of non-UV photons, near-UV photons, and UV photons; and one or more flux shaping structures or angular momentum generators, with or without flux shaping, configured to impart the one or more of the non-UV photons, the near-UV photons, and the UV photons with one or more of spin angular momentum (SAM) and orbital angular momentum (OAM).

Claims

1. A system for 3D printing utilizing non-UV, near-UV, and/or UV photons with or without engineered angular momentum, which may be organized as shaped flux or flux shaping structures of non-UV photons, near-UV photons, and/or UV photons, the system comprising: one or more of a coherent source, a partially-coherent source, and an incoherent source of one or more of non-UV photons, near-UV photons, and UV photons; and one or more flux shaping structures or angular momentum generators, with or without flux shaping, configured to impart the one or more of the non-UV photons, the near-UV photons, and the UV photons with one or more of spin angular momentum (SAM) and orbital angular momentum (OAM); wherein the one or more flux shaping structures or angular momentum generators, with or without flux shaping, are one or more of fabricated as stand-alone structures, fabricated on a package of the one or more of the coherent source, the partially-coherent source, and the incoherent source, and fabricated as an integral part of the one or more of the coherent source, the partially-coherent source, and the incoherent source.

2. The system of claim 1, further comprising means for obtaining one or more of super-resolution and flux-shaped non-UV photons, near-UV photons, and UV photons one or more of fabricated as a stand-alone structure, fabricated on the package of the one or more of the coherent source, the partially-coherent source, and the incoherent source, and fabricated as an integral part of the one or more of the coherent source, the partially-coherent source, and the incoherent source.

3. The system of claim 1, wherein the one or more angular momentum generators or flux shaping structures comprise one or more Spiral Phase Plates made of a non-UV, near-UV, and/or UV transparent material operable for imparting OAM.

4. The system of claim 1, wherein the one or more angular momentum generators or flux shaping structures comprise one or more computer generated diffraction gratings with groove bifurcation comprising one of a fork hologram, a pitchfork hologram, and a fork-like hologram operable for imparting OAM by passing a flux of electromagnetic radiation having incident circular Lauerre-Gaussian through the computer generated diffraction grating.

5. The system of claim 4, wherein the one or more computer generated diffraction gratings comprise one or more phase filters exhibiting super-resolution or flux shaping capabilities.

6. The system of claim 1, wherein the one or more angular momentum generators or flux shaping structures comprise one or more Q-plates operable for imparting one or more of SAM and OAM.

7. The system of claim 6, wherein the one or more Q-plates are implemented dynamically using one or more of liquid crystals, polymers, and subwavelength gratings.

8. The system of claim 1, wherein the one or more angular momentum generators or flux shaping structures comprise one or more thin single domain magnetic needles approximating a magnetic monopole used to generate an optical vortex operable for imparting OAM.

9. The system of claim 1, wherein the one or more of the coherent source, the partially-coherent source, and the incoherent source comprises one of a non-UV, near-UV, and/or UV Laser, a non-UV, near-UV, and/or UV Light Emitting Diode, and a non-UV, near-UV, and/or UV emitting plasma discharge lamp.

10. The system of claim 1, wherein the one or more angular momentum generators or flux shaping structures comprise a Prior Discrete Fourier Transformation (PDFT) phase filter that exhibits super-resolving and/or flux shaping capabilities configured to deliver a super-resolved and/or flux shaped beam configured to be coupled to an optical fiber.

11. The system of claim 1, wherein the 3D printing comprises one of Right-Side-Up SLA 3D printing, and Inverted SLA 3D printing, and a Non-SLA 3D printing that uses a photochemical reaction to print an object.

12. A system for 3D printing utilizing non-UV, near-UV, and/or UV photons with engineered angular momentum or shaped flux, the system comprising: one of a coherent source, a partially-coherent source, and an incoherent source of one or more of non-UV photons, near-UV photons, and UV photons; means for obtaining one or more of super-resolved and flux-shaped non-UV photons, near-UV photons, and super-resolved UV photons; and one or more angular momentum generators or flux shaping structures configured to impart the one or more of the non-UV photons, the near-UV photons and the UV photons with one or more of spin angular momentum (SAM) and orbital angular momentum (OAM); wherein the means for obtaining and the angular momentum generators or flux shaping structures are one or more of fabricated as stand-alone structures, fabricated on a package of the one of the coherent source, the partially-coherent source, and the incoherent source, and fabricated as an integral part of the one of the coherent source, the partially-coherent source, and the incoherent source.

13. The system of claim 12, wherein the one or more angular momentum generators or flux shaping structures comprise one or more Spiral Phase Plates made of a non-UV, near-UV, and/or UV transparent material operable for imparting OAM.

14. The system of claim 12, wherein the one or more angular momentum generators or flux shaping structures comprise one or more computer generated diffraction gratings with groove bifurcation comprising one of a fork hologram, a pitchfork hologram, and a fork-like hologram operable for imparting OAM by passing a flux of electromagnetic radiation having incident circular Lauerre-Gaussian through the computer generated diffraction grating.

15. The system of claim 14, wherein the one or more computer generated diffraction gratings comprise one or more phase filters exhibiting super-resolution or flux-shaping capabilities.

16. The system of claim 12, wherein the one or more angular momentum generators or flux shaping structures comprise one or more Q-plates operable for imparting one or more of SAM and OAM.

17. The system of claim 16, wherein the one or more Q-plates are implemented dynamically using one or more of liquid crystals, polymers, and subwavelength gratings.

18. The system of claim 12, wherein the one or more angular momentum generators or flux shaping structures comprise one or more thin single domain magnetic needles approximating a magnetic monopole used to generate an optical vortex operable for imparting OAM.

19. The system of claim 12, wherein the one of the coherent source, the partially-coherent source, and the incoherent source comprises one of a non-UV, near-UV, and/or UV Laser, a non-UV, near-UV, and/or UV Light Emitting Diode, and a non-UV, near-UV and/or UV emitting plasma discharge lamp.

20. The system of claim 12, wherein the one or more angular momentum generators comprise a Prior Discrete Fourier Transformation (PDFT) phase filter that exhibits super-resolving capabilities configured to deliver a super-resolved beam configured to be coupled to an optical fiber.

21. The system of claim 12, wherein the 3D printing comprises one of Right-Side-Up SLA 3D printing, and Inverted SLA 3D printing, and a Non-SLA 3D printing that uses a photochemical reaction to print an object.

22. The system of claim 12, wherein the means for obtaining the one or more of the super-resolved or flux-shaped non-UV, near-UV, and/or UV photons comprises one or more of (a) lenses designed numerically by modifying a pattern of concentric rings until a target design is obtained, (b) lenses designed using a Prior Discrete Fourier Transformation (PDFT) algorithm, (c) lenses designed using a nonlinear design algorithm that optimizes a zone width of domains of constant phase inside an aperture, either matching a finite set of signal samples or optimizing other components, and (d) super-resolution elements based on super-oscillations.

23. The system of claim 12, wherein the non-UV photons, the near-UV photons, and/or the UV photons are used for treatment of organic or inorganic substances and/or impurities resulting in dimerization or alteration of nucleic acids and/or proteins, accelerated or decelerated polymerization rates, altered polymerization characteristics, and/or lowered activation energy of a chemical reaction, nuclear reaction, or other physical phenomena.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0066] The present invention is illustrated and described herein with reference to the various drawings, in which:

[0067] FIG. 1 is a schematic diagram illustrating two of the most recurrent configurations for a SLA 3D Printer: [A] Inverted SLA System, and [B] Right-Side Up SLA System;

[0068] FIG. 2 is a schematic diagram illustrating a conceptualization of the photo-polymerization process[A] Untreated photo-polymer; [B] Photopolymer treated with UV electromagnetic radiation; [B][1] Untreated photo-polymer depicted as a blend of monomers, oligomers, and photo-initiators; [B][2] When exposed to UV radiation, photo-initiator molecules undergo photolysis creating reactive radicals;

[0069] [B][3] Reactive radicals react with monomers and oligomers forming chains of them; As these chains grow longer and longer, and create crosslinks, the photo-polymer resin changes from a liquid into a solid;

[0070] FIG. 3 is a schematic diagram illustrating a conceptualized circular polarization of an electromagnetic wavethe rotation of the electric field component of the electromagnetic wave around the propagation axis is shown: [A] right circularly polarized, and [B] left circularly polarized;

[0071] FIG. 4 is a schematic diagram illustrating a conceptualized wavefront of an electromagnetic wave carrying Orbital Angular Momentum (OAM)in this specific case, the illustration shows OAM with topological charge, m=1: [A] m=1[B] m=+1.

[0072] FIG. 5 is a schematic diagram illustrating a conceptualized exchange of spin and angular momentum with matter; [A] Spin angular momentum transfer on to an absorbing particle, which acquires a rotational motion; [B] Orbital angular momentum transfer on to an absorbing particle, which will revolve around the OAM axis of the beam of electromagnetic radiation;

[0073] FIG. 6 is a schematic diagram illustrating one exemplary embodiment of the system and method for enhanced treating of matter with engineered angular momentum UV photons;

[0074] FIG. 7 is a schematic diagram illustrating another exemplary embodiment of the system and method for enhanced treating of matter with engineered angular momentum of near-UV and/or UV photons:

[0075] FIG. 8 is a schematic diagram illustrating another exemplary embodiment of the system and method for enhanced treating of matter with engineered angular momentum of near-UV and/or UV photons;

[0076] FIG. 9 is a schematic diagram illustrating another exemplary embodiment of the system and method for enhanced treating of matter with engineered angular momentum of near-UV and/or UV photons;

[0077] FIG. 10 is a schematic diagram illustrating the effect of the invention of using UV photons with engineered angular momentum to treat matter;

[0078] FIG. 11 is a schematic diagram illustrating the domain of application of the current innovation;

[0079] FIG. 12 is a schematic diagram illustrating the use of the innovation within a SLA 3D printer;

[0080] FIG. 13 is a schematic diagram illustrating the use of the innovation within a SLA 3D printer;

[0081] FIG. 14 is a schematic diagram illustrating the use of the innovation within a SLA 3D printer;

[0082] FIG. 15 is a schematic diagram illustrating the use of the innovation within a SLA 3D printer.

DETAILED DESCRIPTION OF THE INVENTION

[0083] Referring now specifically to FIG. 6, one representation of the invention is an apparatus [A], [B] comprising a source of UV photons [1], one or more stand alone angular momentum generators [2] configured to deliver UV photons with optimized spin angular momentum (SAM), org orbital angular momentum (OAM), and/or a SAM/OAM [3] combination to target organic or inorganic substance and/or impurity. The angular momentum generator can have different forms [a], [b], [c], and [d].

[0084] Referring now specifically to FIG. 6 [2a] UV photons can acquire optimized OAM with a Spiral Phase Plate made of UV transparent material with refractive index n, having an inhomogeneous thickness, h proportional to the azimuthal angle

[00004]$h=h_s.Math.\frac{}{2.Math.}+h_0$

where h.sub.s is the step height, and h.sub.0 is the base height. When a beam of electromagnetic radiation (Gaussian) with plane phase distribution passes through this OAM generator, an optical vortex charge q is imprinted according to

[00005]$q=\frac{h_s\left(n-n_0\right)}{}$

[0085] This means that the output beam of electromagnetic radiation will carry OAM per photon equal to qh, where h is the Reduced Planck's constant. For a given electromagnetics wavelength in the UV range of the electromagnetic spectrum, then the vortex charge q can be engineered by controlling the optical step h.sub.s.

[0086] Referring now specifically to FIG. 6 [2b] UV photons can acquire optimized OAM by passing flux of electromagnetic radiation having incident circular Lauerre-Gaussian through a computer generated diffraction grating with groove bifurcation known as fork holograms, pitchfork holograms, or fork-like holograms. If as single groove divides into +1 branches then the n-order diffracted beam of electromagnetic radiation acquires the optical vortex (photons carrying OAM) with topological charge

[0087] l=n

[0088] [2b] shows fork hologram with a single groove that divides into 1 branch, therefore =1. For a given electromagnetic wavelength in the UV range of the electromagnetic spectrum, then the topological vortex charge I can be engineered by controlling the number of branches. For operation for a given electromagnetic wavelength in the UV range, the diffraction grating needs to be fabricated with features equal of smaller than said wavelength .

[0089] Computer generated holograms that function as angular momentum generators can be designed and fabricated as phase filters that also exhibit super-resolving capabilities. Super-resolution diffracting elements are designed numerally by modifying a pattern of concentric rings similar to those illustrated in [2c]. Super-resolved Phase filters that function as angular momentum generators can be based on the so-called use a design methods based on the so-called Prior Discrete Fourier Transformation (PDFT). For operation for a given electromagnetic wavelength A in the UV range, concentric ring patterns, and PDFT patterns must be fabricated with features equal of smaller than said wavelength .

[0090] [2c] shows a Q-plate used as SAM/OAM angular momentum generator. Similarly to a Spiral Phase Plate [2a], a Q-plate influences electromagnetic radiation by making it interact with matter that is both optically inhomogeneous and anisotropic. The design of a Q-plate can be implemented dynamically using liquid crystals, and polymers, or subwavelength gratings. For operation for a given electromagnetic wavelength in the UV range, the patterns created with liquid crystals or polymers, and the features of the gratings must be equal of smaller than said wavelength .

[0091] [2d] shows a thin single domain magnetic needle approximating a magnetic monopole used to generate an optical vortex (OAM carrying photons) angular momentum generator. A beam of electromagnetic radiation is passed through a through a round aperture upon which a thin-tip magnetic rod is secured. OAM tuning is controlled by the magnetization of the single domain magnetic needle.

[0092] Referring now specifically to FIG. 7, one representation of the invention is an apparatus [A], [B], and [C] comprising a source of UV photons such as, but not limited to a UV Laser, a UV Light Emitting Diode, or a UV emitting plasma discharge lamps [1], one or more stand alone angular momentum generators [2] configured to deliver UV photons with optimized spin angular momentum (SAM), org orbital angular momentum (OAM), and/or a SAM/OAM [3] combination to target organic or inorganic substance and/or impurity. In this particular incarnation, the idea is to have a design for an optimized angular generator such as a Spiral Phase Plate, a hologram, a Q-plate, or a single domain magnetic needle approximating a magnetic monopole that can be fabricated and scaled using Very large Scale Integration (VLSI) fabrication techniques so that the device can be fabricatedas an array or not- onto the surface of a freestanding UV transparent medium, FIG. 7 [A][2], or onto the surface of a UV transparent window (an aperture) such as the UV transparent window of a packaged UV Laser Diode, FIG. 7 [B][2]. Since hologram features must be equal or smaller then the UV wavelength (400 nm or smaller), then VLSI fabrication techniques can be used to integrate an optimized angular generator such as a Spiral Phase Plate, a hologram, a Q-plate, or a single domain magnetic needle approximating a magnetic monopole onto the surface of a solid state die (Laser Diode, Light Emitting Diode, Microplasma Discharge Bulb as shown in FIG. 7 [C][2].

[0093] Referring now specifically to FIG. 8, one representation of the invention is an apparatus comprising a source of UV photons such as, but not limited to a UV Laser, a UV Light Emitting Diode, or a UV emitting plasma discharge lamps [1], an angular momentum generator that is also a PDFT phase filter or similar phase/diffractive filter that exhibits super-resolving capabilities [2] configured to deliver a super-resolved beam of UV photons with optimized spin angular momentum (SAM), org orbital angular momentum (OAM), and/or a SAM/OAM combination [3] that can be efficiently coupled to fiber optics [4] to target organic or inorganic substance and/or impurity. In this particular incarnation PDFT patterns must be fabricated with features equal of smaller than said wavelength .

[0094] Referring now specifically to FIG. 9, one representation of the invention is an apparatus comprising a source of UV photons such as, but not limited to a UV Laser, a UV Light Emitting Diode, or a UV emitting plasma discharge lamps [1], an angular momentum generator that is also a PDFT phase filter or phase/diffractive filter that exhibits super-resolving capabilities [2] configured to deliver a super-resolved beam of UV photons with optimized spin angular momentum (SAM), org orbital angular momentum (OAM), and/or a SAM/OAM combination [3] that can be efficiently coupled to fiber optics [4] to target organic or inorganic substance and/or impurity. In this particular incarnation, the idea is to have a design for an angular momentum generator that is also a PDFT phase filter that exhibits super-resolving capabilities that can be fabricated and scaled using Very large Scale Integration (VLSI) fabrication techniques so that the device can be fabricatedas an array or notonto the surface of a freestanding UV transparent medium, FIG. 9 [A][2], or onto the surface of a UV transparent window (an aperture) such as the UV transparent window of a packaged UV Laser Diode, FIG. 9 [B][2]. Since the features of the momentum generator/PDFT super-resolving phase filter must be equal or smaller then the UV wavelength (400 nm or smaller), then VLSI fabrication techniques can be used to integrate it onto the surface of a solid state die (Laser Diode, Light Emitting Diode, Microplasma Discharge Bulb as shown in FIG. 9 [C][2].

[0095] Referring now specifically to FIG. 10, one representation of the conceptualized exchange of optimized spin angular momentum (SAM) [C] and/or optimized orbital angular momentum (OAM) [D] carried by UV photons that interact with matter. In this particular example, matter is represented by a UV curable polymer that results from the linking of monomers, oligomers and UV excited photo initiators. UV curable precursors [A][1], [B][1], [C][1], and [D][1] are inert until UV photons carrying sufficient energy can be absorbed by photoinitiators [B][2], [C][2], and [D][2], which will link monomers and oligomers into a chain of polymers [B][3], [C][3], and [D][3]. UV photons carrying optimized spin angular momentum (SAM) and/or optimized orbital angular momentum (OAM) will transfer their momentum to matter and so increase the probability for photoinitiators to absorb these photons [C][2], and [D][2]. This results in an enhanced polymerization [C][3], and [D][3].

[0096] Referring now specifically to FIG. 11, the representation of range of operation of the invention in the UV segment of the electromagnetic spectrum: from 400 nm to 10 nm. Illustrated are also the concept of Horizontal Scalability (HS), and Vertical Scalability (VS). HS implies a general design that can be scaled to operate at different wavelength within said electromagnetic spectrum. VS implies a general design that can integrated at different system levels.

[0097] Referring now specifically to FIG. 12, the representation of the use the invention to enable a Right-Side Up SLA 3D printer with the ability to use UV photons carrying engineered angular momentum. Illustrated is also the concept of Vertical Scalability (VS), which implies a general design that can be integrated at different system levels.

[0098] Referring now specifically to FIG. 13, the representation of the use the invention to enable an Inverted SLA 3D printer with the ability to use UV photons carrying engineered angular momentum. Illustrated is also the concept of Vertical Scalability (VS), which implies a general design that can be integrated at different system levels.

[0099] Referring now specifically to FIG. 14, the representation of the use the invention to enable a Right-Side Up SLA 3D printer with the ability to use a super-resolved (sub-wavelength) beam or flux of UV photons to achieve higher resolution, accuracy and precision. Illustrated is also the concept of Vertical Scalability (VS), which implies a general design that can be integrated at different system levels.

[0100] Referring now specifically to FIG. 15, the representation of the use the invention to enable an Inverted SLA 3D printer with the ability to use a super-resolved (sub-wavelength) beam or flux of UV photons to achieve higher resolution, accuracy and precision. Illustrated is also the concept of Vertical Scalability (VS), which implies a general design that can be integrated at different system levels.

[0101] One further embodiment of the invention is comprising a source of near-UV and/or UV photons, one or more stand alone angular momentum generators configured to deliver near-UV and/or UV photons with or without optimized spin angular momentum (SAM), or orbital angular momentum (OAM), and/or a combined SAM/OAM, which includes the an algorithm and/or design to achieve super-resolution with near-UV and/or UV radiation (coherent or incoherent), such as the super-resolution algorithm called Prior Discrete Fourier Transformation (PDFT).

[0102] One further embodiment of the invention is comprising a source of near-UV and/or UV photons, one or more stand alone angular momentum generators configured to deliver near-UV and/or UV photons with or without optimized spin angular momentum (SAM), or orbital angular momentum (OAM), and/or a combined SAM/OAM, which includes the an algorithm and/or design to achieve super-resolution with near-UV and/or UV radiation (coherent or incoherent), such as [1] lenses designed numerically by modifying a pattern of concentric rings until the target design is obtained, [2] nonlinear design algorithms, which optimize the zone width of domains of constant phase inside the DOE aperture, either matching a finite set of signal samples, or optimizing additional components of a more complex cost function, and/or [3] super-resolution elements based on the concept of super-oscillations.

[0103] Although the present invention is illustrated and described herein with reference to preferred embodiments and specific examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples may perform similar functions and/or achieve like results. All such equivalent embodiments and examples are within the spirit and scope of the present invention, are contemplated thereby, and are intended to be covered by the following non-limiting claims for all purposes.