arXiv subjects

Hayden K. Taylor

Publications and source records attributed to Hayden K. Taylor.

6 recordsLinked to original sources

arXiv2026

Co-optimization of Diffusive and Tomographic Blur in Computed Axial Lithography via Experimental Kernel Identification

Computed Axial Lithography is a volumetric additive manufacturing method that selectively cures photosensitive resin through the 3D superposition of patterns of light, offering advantages over layer-based processes including rapid print times, reduced layer artifacts, and compatibility with high-viscosity materials. However, diffusive effects, primarily those of free-radical quenchers such as oxygen, blur the boundary between cured and uncured regions, limiting resolution and preventing the reproduction of sharp, high-spatial-frequency features. By comparing micro-CT data to computational dose models convolved with kernels across a range of diffusivities, we establish a framework for extracting a single diffusion kernel from any standard uncorrected print to account for all observed deviations from the target. In this work, we correct diffusion-induced blurring by co-optimizing for its effects alongside the inherent blur of the computed tomography reconstruction, demonstrating improved fidelity over previous approaches of pre-compensating the target geometry via deconvolution.

eess.IV↗

arXiv2026

Scale-invariant projection optimization in tomographic volumetric additive manufacturing

Tomographic volumetric additive manufacturing (TVAM) requires projection patterns that achieve high in-part fidelity while suppressing unintended exposure outside the target. We present a scale-invariant projection optimization framework (SiPO) that decouples projection shape from absolute dose scaling. The method formulates projection design as a linear-fractional program based on normalized conformity and spillage metrics, which is converted into a linear program via the Charnes-Cooper transformation. Two practical deterministic cases are introduced for process control: minimizing dose spillage under strict material tolerances and maximizing target conformity under hard inhibition constraints. A matrix-free primal-dual hybrid gradient solver enables large-scale implementation. Numerical results demonstrate that the framework provides a clear trade-off between target fidelity and process separation and remains effective under 3D blur-aware forward models.

cs.CE↗

arXiv2024

Tomographic projection optimization for volumetric additive manufacturing with general band constraint Lp-norm minimization

Tomographic volumetric additive manufacturing is a rapidly growing fabrication technology that enables rapid production of 3D objects through a single build step. In this process, the design of projections directly impacts geometric resolution, material properties, and manufacturing yield of the final printed part. Herein, we identify the hidden equivalent operations of three major existing projection optimization schemes and reformulate them into a general loss function where the optimization behavior can be systematically studied, and unique capabilities of the individual schemes can coalesce. The loss function formulation proposed in this study unified the optimization for binary and greyscale targets and generalized problem relaxation strategies with local tolerancing and weighting. Additionally, this formulation offers control on error sparsity and consistent dose response mapping throughout initialization, optimization, and evaluation. A parameter-sweep analysis in this study guides users in tuning optimization parameters for application-specific goals.

math.OC↗

arXiv2024

Multi-beam phase mask optimization for holographic volumetric additive manufacturing

The capability of holography to project three-dimensional (3D) images and correct for aberrations offers much potential to enhance optical control in light-based 3D printing. Notably, multi-beam multi-wavelength holographic systems represent an important development direction for advanced volumetric additive manufacturing (VAM). Nonetheless, searching for the optimal 3D holographic projection is a challenging ill-posed problem due to the physical constraints involved. This work introduces an optimization framework to search for the optimal set of projection parameters, namely phase modulation values and amplitudes, for multi-beam holographic lithography. The proposed framework is more general than classical phase retrieval algorithms in the sense that it can simultaneously optimize multiple holographic beams and model the coupled non-linear material response created by co-illumination of the holograms. The framework incorporates efficient methods to evaluate holographic light fields, resample quantities across coordinate grids, and compute the coupled exposure effect. The efficacy of this optimization method is tested for a variety of setup configurations that involve multi-wavelength illumination, two-photon absorption, and time-multiplexed scanning beam. A special test case of holo-tomographic patterning optimized 64 holograms simultaneously and achieved the lowest error among all demonstrations. This variant of tomographic VAM shows promises for achieving high-contrast microscale fabrication. All testing results indicate that a fully coupled optimization offers superior solutions relative to a decoupled optimization approach.

physics.optics↗

arXiv2023

Fundamental Scaling Relationships in Additive Manufacturing and their Implications for Future Manufacturing Systems

The field of additive manufacturing (AM) has advanced considerably over recent decades through the development of novel methods, materials, and systems. However, as the field approaches maturity, it is relevant to investigate the scaling frontiers and fundamental limits of AM in a generalized sense. Here we propose a simplified universal mathematical model that describes the essential process dynamics of many AM hardware platforms. We specifically examine the influence of several key parameters on total manufacturing time, comparing these with performance results obtained from real-world AM systems. We find a inverse-cubic dependency on minimal feature size and a linear dependency on overall structure size. These relationships imply how certain process features such as parallelization and process dimensionality can help move toward the fundamental limits. AM methods that are capable of varying the size of deposited voxels provide one possibility to overcome these limits in the future development of AM. We also propose a new framework for classifying manufacturing processes as "top-down" vs "bottom-up" paradigms, which differs from the conventional usage of such terms, and present considerations for how "bottom-up" manufacturing approaches may surpass the fundamental limits of "top-down" systems.

cond-mat.mtrl-sci↗

arXiv2017

Computed Axial Lithography (CAL): Toward Single Step 3D Printing of Arbitrary Geometries

Most additive manufacturing processes today operate by printing voxels (3D pixels) serially point-by-point to build up a 3D part. In some more recently-developed techniques, for example optical printing methods such as projection stereolithography [Zheng et al. 2012], [Tumbleston et al. 2015], parts are printed layer-by-layer by curing full 2d (very thin in one dimension) layers of the 3d part in each print step. There does not yet exist a technique which is able to print arbitrarily-defined 3D geometries in a single print step. If such a technique existed, it could be used to expand the range of printable geometries in additive manufacturing and relax constraints on factors such as overhangs in topology optimization. It could also vastly increase print speed for 3D parts. In this work, we develop the principles for an approach for single exposure 3D printing of arbitrarily defined geometries. The approach, termed Computed Axial Lithgography (CAL), is based on tomographic reconstruction, with mathematical optimization to generate a set of projections to optically define an arbitrary dose distribution within a target volume. We demonstrate the potential ability of the technique to print 3D parts using a prototype CAL system based on sequential illumination from many angles. We also propose new hardware designs which will help us to realize true single-shot arbitrary-geometry 3D CAL.

cs.GR↗