A novel approach to microfabrication based on stereolithography was presented. This fabrication process is referred to as, ‘Exposure Controlled Projection Lithography’ (ECPL). In the ECPL process, incident radiation, patterned by a dynamic mask, passes through a transparent substrate to cure photopolymer resin. By controlling the amount of exposure, the height field of the cured film can be controlled. An ECPL system was designed and assembled. Factors affecting the accuracy of the ECPL process in fabricating micron shaped features were identified and studied. A real-time in-situ photopolymerization monitoring system was designed and assembled within the ECPL system to identify the sources of variations present in the system. Parts are fabricated from the ECPL process because of polymerization (or cross-linking) of monomer resin using light energy. Photopolymerization is a complex process involving coupling between several phenomena. This process was modeled by utilizing an understanding of the known polymerization reaction kinetics with incorporating the effects of oxygen inhibition and diffusion. A material response model and a simulation tool to estimate the shape of a cured part resulting from photopolymerization was created. This model was used to formulate a process-planning method to estimate the manufacturing process inputs required to cure a part of desired shape and dimensions. The process planning method was validated through simulations and experiments.

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Textile UV-radiation sensors has lately been introduced to the field of smart textiles. Inkjet printing has been used as means of application due to the effective and resource efficient process. UV-LED radiation curing has been used in combination with inkjet printing in favour of low energy requirements, solvent free solution and reduced risk of clogging in the print heads. The problems arising when exposing photochromic prints to UV-radiations are that oxygen inhibition during the curing and photo-oxidation in the print reduces the prints ability to develop colour. It is the oxygen in the air in combination with UV-radiation that gives the photo-oxidating behavior. The aim of the study is to with the aid of physical protection reduce the effect of oxygen inhibition and photo-oxidation in the prints. Three types of physical treatments were used, wax coating, protein based impregnation and starch based impregnation. Treatments were applied before curing as well as after curing and the colour development after activation during 1 min of UV-radiation was measured with a spectrophotometer. Multiple activations were also tested to see how the treatments affected the fatigue behaviour of the prints over time. The aim was to have as high colour development as possible reflecting reduced oxygen inhibition and photo-oxidation. Results showed significantly higher colour development for samples treated with wax and whey powder before curing, but reduced colour development for amylose impregnation. Over time whey powder before curing showed highest colour development due to highest initial colour development. Lowest fatigue was seen for washed samples containing the chemical stabiliser HALS, showing an increased colour development. In reference to earlier studies the protective properties of wax and whey powder is due to their oxygen barrier properties protecting the print. The tested treatments have shown that it is possible to reduce the effect of photo-oxidation during curing leading to prints giving higher colour development. This gives a great stand point when improving existing and future application of photochromic prints on textiles.