Computed Tomography-Based Volumetric Additive Manufacturing: Development of a Model Based on Resin Properties and Part Size Interrelationship—Part I

This study presents an analytical description of the computed tomography-based volumetric additive manufacturing (VAM) process, with an emphasis on the impact of resin properties on product dimensions. The main issue addressed in this study is the assessment of the dimensional limitation of the objects produced using the VAM process, which is usually reported to be of the order of one centimeter. An analytical model is introduced to predict the product size based on the resin property (penetration depth—Dp), vial size (radius), and the duration of part formation, and the results indicate significant correlations among these parameters. A method of Dp measurement and analysis that is appropriate for the VAM process is also introduced. Mathematical justification is provided along with experimental verification for the effects of the main governing factor, Dp, on the maximum possible product size. Multiple criteria are also introduced for selecting the appropriate size of the resin container (vial) based on the desired object size and the value of Dp. It was found that the Dp is a crucial factor in analysis and experimentation in the VAM process, and its value is fundamentally different from the one obtained in the conventional polymerization AM methods. The product dimension based on the resin property, vial size, and time for the formation of the part is introduced by the analytical model. This model provides valuable insights into the complex interplay of factors influencing VAM outcomes and can facilitate informed decision-making in material selection and process design.