Additive & Photopolymerization

Continuous Liquid Interface Production (CLIP) & Dead-Zone Calculator

Model oxygen inhibition dead-zone thickness ($d_z$), continuous Z-elevator vertical build speed ($v_z$), hydrodynamic resin suction forces, and Jacque-Beer exposure doses for continuous, layerless vat photopolymerization.

1. Input Parameters

Projector Peak UV Irradiance $I_0$ (mW/cm²):

DLP/LCD light engine intensity at the resin window interface (405nm).

Critical Resin Cure Dose $E_c$ (mJ/cm²):

Gel-point threshold dose required to initiate cross-linking.

Resin Depth of Penetration $D_p$ (µm):

Jacobs working curve optical penetration depth constant ($1/e$ absorption).

Window Oxygen Permeability / Flux $P_{O2}$ (Barrer):

Oxygen permeability of the fluoropolymer (e.g. Teflon AF2400 / PMP).

Liquid Resin Dynamic Viscosity $\mu$ (mPa·s):

Viscosity at operating temperature (lower viscosity enables faster refill).

Equivalent Cross-Section Part Radius $R$ (mm):

Maximum solid footprint radius for resin hydrodynamic reflow.

2. Calculation Results

Oxygen Dead-Zone ($d_z$)

0.0 µm

Max Continuous Build Speed ($v_z$)

0.0 mm/hr

Hydrodynamic Suction ($\Delta P$)

0.0 kPa

Cavitation / Window Adhesion Risk

Safe Continuous Flow

Polymerization Rate ($R_p$)

0.00 s⁻¹

Cure Depth Beyond Dead-Zone

0.0 µm

3. Dynamic Visualizer & CAM Preview

4. Engineering Notes & Physics Specifications

CLIP Photopolymerization & Stefan Hydrodynamic Adhesion:

Dead-Zone Formation: Oxygen diffusing through the permeable window quenches free-radical photoinitiators: $d_z \approx \sqrt{\frac{D_{O_2} [O_2]_0}{k_{cure} [PI^*]}}$. A stable dead-zone ($20 - 50\,\mu\text{m}$) prevents resin from adhering to the vat window.
Continuous Elevator Velocity Limit: The continuous vertical speed is bounded by optical curing time: $v_{z,\text{max}} = \frac{D_p}{\tau_{cure}}$. Typical industrial CLIP speeds reach $150 - 600\text{ mm/hr}$.
Stefan Lubrication Suction Force: Liquid resin flowing radially creates negative pressure: $\Delta P = \frac{3 \mu v_z R^4}{2 d_z^3}$. If $\Delta P$ exceeds the cavitation limit ($> 85\text{ kPa}$), vapor bubbles cause part tearing.

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