Tailored TEMp0 beams for large size 3-D laser prototyping

The Laser-Lithography technique allows the fabrication of complex objects having microsizes by selectively solidifying polymeric materials layer by layer upon exposure to a focused Gaussian laser beam having a beam propagation factor M²=1. We can expect that extension of this technique to large sizes 3-D prototyping comes up against a large increase in the design time. A possible solution is the increase in the focused spot size, but unfortunately at the price of a great reduction in the longitudinal resolution due to the resulting increase in the depth of focus. To overcome these difficulties, we propose the use of a rectified TEM_p0 beam allowing the obtaining of a Gaussian beam intensity profile in the focus plane of a lens. The reshaped TEM_p0 beam has a beam propagation factor M²≈(2p+1), and this yields to a relative improvement of the longitudinal resolution although the spot size is increased for reducing the processing time.