A virtual visualization method for improving the manufacturing accuracy based VPP 3D printers.

Compared to traditional vat photopolymerization 3D printing methods, pixel blending technique provides greater freedom in terms of user-defined lighting sources. Based on this technology, scientists have conducted research on 3D printing manufacturing for elastic materials, biologically inert materials, and materials with high transparency, making significant contributions to the fields of portable healthcare and specialty material processing. However, there has been a lack of a universal and simple algorithm to facilitate low-cost printing experiments for researchers not in the 3D printing industry. Here, we propose a mathematical approach based on morphology to simulate the light dose distribution and virtual visualization of parts produced using grayscale mask vat photopolymerization 3D printing technology. Based on this simulation, we develop an auto-correction method inspired by circle packing to modify the grayscale values of projection images, thereby improving the dimensional accuracy of printed devices. This method can significantly improve printing accuracy with just a single parameter adjustment. We conducted experimental validation of this method on a vat photopolymerization printer using common commercial resins, demonstrating its feasibility for printing high precision structures. The parameters utilized in this method are comparatively simpler to acquire compared to conventional techniques for obtaining optical parameters. For researchers in non-vat photopolymerization 3D printing industry, it is relatively user-friendly.