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Revolutionizing Solar, Battery Technology, and MicroOptics: Integrating Linear Volumetric 3D Printing and Subzero Molding

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Conference Abstract: We introduce a pioneering integration of Volumetric 3D Printing, Subzero Molding, and Agile methodologies, reshaping the landscape of 3D solar and battery cell manufacturing. This innovative approach, leveraging photopolymers with fused silica and glass waste powder, yields cost-effective nano and microstructures across large areas, enhancing precision, durability, and efficiency. Key outcomes include Microstructured 3D glass and 3D glass foam, both holding immense potential for elevating solar and battery cell performance.
Volumetric 3D Printing excels in creating precise structures with heightened resolution accuracy and speed. The method selectively solidifies UV-cured liquid resin while levitating in the resin, uniquely functional in 0 G conditions. Complementarily, the subzero molding process produces lightweight glass foam and solid ceramic, glass, and soon metal structures, enhancing energy storage and solar energy manufacturing. Patents filed in 2017 predate public awareness of Lawrence Livermore National Laboratory's (LLNL) laser-based volumetric additive manufacturing, advancing intricate polymer and glass structures. By stitching together High-Resolution Molds through Volumetric 3D Printing, we achieve 7-700nm surface resolution, enabling one-shot molding of glass with nano and microstructures over large areas. Potential markets include Solar, DMD, Optics, Glass Microchips, and Custom Glass Substrates for microchip placement which Intel is working on.
Our breakthrough involves mixing 50% SIO2 with 50% Tethon Genesis Development High Load Resin, facilitating printing/casting/molding/imprinting at room and subzero temperatures based on the application. Subzero Molding addresses glass cracking and warpage issues associated with photo-initiating large areas in one shot, a common challenge. This solution is also applied to the One Shot Volumetric 3D Printing process.
In summary, the amalgamation of 1 Step Volumetric 3D Printing and Subzero Molding propels Next Generation Micro-Optics, Solar, microstructured 3D glass, 3D glass foam, and advanced coatings, marking significant strides in the development of high-efficiency solar cells, energy-dense battery cells, and AGILE Glass Micro-Optics for Next Generation Solar.