We are developing photopolymer resins with a toughness exceeding 25 MJ/m3, with a strain capacity of >200%, which are low odor, and which can be additively manufactured into a mesh of effective density <50 kg/m3 with individual strut thickness of <250 µm. We are optimizing placement of individual Digital Micromirror Device (DMD) chips (visual field overlap, optics train, staggering, rotation) in LightBars™, which consist of arrays of up to 64 DMDs with sufficient overlap to cure part layers at an anticipated 10 mm/sec to cover 500 mm wide at a voxel resolution of <200 µm such that each voxel is “patterned” by >1,000 different mirrors. Different resins have been tailored with different additive cocktails for rapid manufacturing at different wavelengths ranging from 355 nm to 385 nm to 405 nm.
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