Suppressing the Step Effect of 3D Printing for Constructing Contact Lenses
Suppressing the Step Effect of 3D Printing for Constructing Contact Lenses
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DOI：
10.1002/adma.202107249
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发表时间：
2021-11
影响因子：
29.4
通讯作者：
Yu Zhang;Lei Wu;Miaomiao Zou;Lidian Zhang;Yanlin Song
中科院分区：
文献类型：
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作者：
Yu Zhang;Lei Wu;Miaomiao Zou;Lidian Zhang;Yanlin Song
3D打印被认为是构建复杂3D结构的可持续方法。然而，传统的逐点或逐层增材制造模式不可避免地会产生台阶效应，这仍然是实现3D样品光滑性和均匀性的障碍。在这里，提出了一种基于数字光处理（DLP）技术的连续液膜限制3D打印策略来制造高精度3D结构。通过控制液-固界面的限制和连续打印模式，粘附到固化结构上的液体膜被吸入固化层结构中，其中粘附到固化结构上的过量树脂被刮除，其中消除了阶梯效应并且避免了后清洗。限制液膜的形态和尺寸可以通过油墨性质和印刷参数来很好地调节，以优化表面光滑度和印刷保真度。此外，还可抑制热积聚和热扩散，确保长期打印稳定性。可以打印中心厚度为135 µm的厘米级接触透镜结构，与商业结构相当，具有极高的光滑度（低于1.3 nm）、均匀的机械特性、生物相容性和高光学性能，成像分辨率高达228.1 lp mm−1。
3D printing has been considered as a sustainable method to construct complicated 3D structures. However, the step effect induced by the traditional point‐by‐point or layer‐by‐layer additive manufacturing mode inevitably occurs and remains an obstacle to realizing the smoothness and uniformity of 3D samples. Here, a continuous liquid film confined 3D printing strategy is proposed to fabricate high‐precision 3D structures based on the Digital Light Processing (DLP) technology. With the control of the confinement of the liquid–solid interface and the continuous printing mode, liquid film adhering to the cured structure is sucked into the cured layer structures with excess resin adhering to the cured structure scraping off, where the step effect is eliminated and post‐washing is avoided. The morphology and dimension of the confined liquid film can be well regulated by ink properties and printing parameters to optimize the surface smoothness and printing fidelity. In addition, heat accumulation and thermal diffusion are also suppressed, ensuring the long‐term printing stability. A centimeter‐scale contact lens structure with central thickness of ≈135 µm comparable to commercial ones can be printed, which possesses extreme smoothness (sub 1.3 nm), homogeneous mechanical characteristic, biocompatibility, and high optical properties with imaging resolution of up to 228.1 lp mm−1.