Dynamic Interface Printing
arxiv(2024)
Abstract
Additive manufacturing is an expanding multidisciplinary field encompassing
applications including medical devices, aerospace components, microfabrication
strategies, and artificial organs. Among additive manufacturing approaches,
light-based printing technologies, including two-photon polymerization,
projection micro stereolithography, and volumetric printing, have garnered
significant attention due to their speed, resolution and/or potential
applications for biofabrication. In this study, we introduce dynamic interface
printing (DIP), a new 3D printing approach that leverages an acoustically
modulated, constrained air-liquid boundary to rapidly generate cm-scale
three-dimensional structures within tens of seconds. Distinct from volumetric
approaches, this process eliminates the need for intricate feedback systems,
specialized chemistry, or complex optics while maintaining rapid printing
speeds. We demonstrate the versatility of this technique across a broad array
of materials and intricate geometries, including those that would be impossible
to print via conventional layer-by-layer methods. In doing so, we demonstrate
the rapid fabrication of complex structures in-situ, overprinting, structural
parallelisation, and biofabrication utility. Moreover, we showcase that the
formation of surface waves at this boundary enables enhanced mass transport,
material flexibility, and permits three-dimensional particle patterning. We
therefore anticipate that this approach will be invaluable for applications
where high resolution, scalable throughput, and biocompatible printing is
required.
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