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Most additive manufacturing processes today operate by printing voxels (3Dpixels) serially point-by-point to build up a 3D part. In some morerecently-developed techniques, for example optical printing methods such asprojection 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 techniquewhich is able to print arbitrarily-defined 3D geometries in a single printstep. If such a technique existed, it could be used to expand the range ofprintable geometries in additive manufacturing and relax constraints on factorssuch as overhangs in topology optimization. It could also vastly increase printspeed for 3D parts. In this work, we develop the principles for an approach forsingle exposure 3D printing of arbitrarily defined geometries. The approach,termed Computed Axial Lithgography (CAL), is based on tomographicreconstruction, with mathematical optimization to generate a set of projectionsto optically define an arbitrary dose distribution within a target volume. Wedemonstrate the potential ability of the technique to print 3D parts using aprototype CAL system based on sequential illumination from many angles. We alsopropose new hardware designs which will help us to realize true single-shotarbitrary-geometry 3D CAL.

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