In-Situ Ultrasonic Monitoring for Process Monitoring of Digital Light Process 3D Printing

Abstract

Digital Light Processing (DLP) 3D printing is a widely used vat photopolymerization (VPP) technique known for its ability to produce intricate geometries with a broad range of mechanical properties. However, ensuring consistent, defect-free parts remains challenging, primarily due to shrinkage, partial curing, and uneven exposure. In this work, an in-situ ultrasonic monitoring system is introduced which continually assesses each newly formed layer in real-time. By analyzing how ultrasonic waves travel through each layer, internal flaws down to 0.249 mm² were reliably identified, and dimensional accuracy of approximately 0.2 mm was achieved. Identifying defects precisely when they emerge allows immediate corrective actions, significantly reducing material waste and post-processing efforts. This approach provides a promising solution for enhanced reliability and efficiency of DLP manufacturing, particularly in fields such as biomedical engineering and microfluidics, where precision and material integrity are critical.