High-resolution membrane DLP 3D printing platform for scaled porous models with tiling and bubble mitigation
A custom membrane-based dynamic light processing (m-DLP) 3D printing platform offering 2–3 μm feature resolution, enhanced with projection tiling and vibrational separation-force mitigation to produce scaled porous digital models (50–100 cm² area) with reduced bubble formation and higher yield. Combines sub-5 μm resolution, faster throughput than two-photon polymerization, and lower equipment cost than competing photopolymerization methods.
Overview
This offering is a high-resolution membrane-based dynamic light processing (m-DLP) 3D printing platform developed at Brigham Young University. The technology targets the production of scaled porous digital models with micron-scale features, addressing a key limitation of conventional m-DLP printing: separation forces between the membrane and printed layer that restrict build area and cause bubble formation. By integrating projection tiling with active vibrational separation-force mitigation, the platform enables larger print areas at high resolution while improving yield and reducing defects.
The platform is positioned for research and industry partners needing porous structures such as tissue scaffolds, filtration media, membrane prototypes, and other micro-architectured parts. Compared with two-photon polymerization (sub-micron resolution but voxel-by-voxel, slow, and ~$150k equipment) and non-membrane DLP (fast but $35k base equipment).
Technical specifications
Current capabilities:
- Negative feature resolution down to 2 μm; positive feature resolution down to 3 μm
- Build volume of 1 × 2 × 1 cm in approximately 45 minutes
- Membrane-based DLP architecture with layer-by-layer photopolymerization
Planned enhancements:
- Projection tiling to expand the layer-print area, enabling target build areas of 50–100 cm² at 1 cm height
- Vibrational separation-force mitigation using optimized vibrational modes of the print head to introduce asymmetric separation, reduce resin entrainment, and minimize bubble formation and accumulation
Target output specifications:
- Build area: 50–100 cm²
- Height: up to 1 cm
- Fiber diameters: 1–30+ μm
- Pore sizes: 50–500 μm
Advantages over alternative photopolymerization methods:
- Higher resolution than non-membrane DLP (~100 μm)
- Faster throughput than two-photon polymerization
- Lower equipment cost than two-photon polymerization systems
Technology readiness level
The base m-DLP printing method is established in the lab, with demonstrated 2 μm negative and 3 μm positive feature resolution and a working 1 × 2 × 1 cm build volume. The two proposed enhancements, projection tiling and vibrational separation-force mitigation, are at an early-to-mid development stage. Validation will proceed in parallel along two task tracks: (1) developing hardware and software for projection tiling and optimizing tiled-projection optics at scale, and (2) investigating vibrational effects on bubble formation and separation force at high time scales, then deriving optimized vibrational modes to minimize separation force and increase yield. The estimated cost is ~$50k per year for two years, primarily covering graduate student labor and hardware. Sponsored research is identified as the ideal partnership model, with openness to pilot engagements and co-development arrangements.
About Brigham Young University
Brigham Young University is a large private research university in Provo, Utah, with an undergraduate-focused profile and selective graduate programs. Corporate partners engage through sponsored research, student capstone design programs, and internship pipelines that deliver hands-on solutions and hiring pathways. Proximity to the Wasatch Front’s growing technology corridor enables close collaboration, on-site visits, and year‑round recruiting, while campus prototyping shops and test laboratories support rapid iteration. Research is supported by competitive federal funding, including the National Science Foundation and the National Institutes of Health. A dedicated technology transfer office manages IP, licensing, and startup formation, and standard agreements streamline industry collaboration.
delivered to your inbox.