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Rapid, large-volume, thermally controlled 3D printing using a mobile liquid interface.

David A Walker1,2, James L Hedrick2,3, Chad A Mirkin4,2,3

  • 1Department of Chemistry, Northwestern University, Evanston, IL 60208, USA.

Science (New York, N.Y.)
|October 19, 2019
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Summary

This study introduces a novel 3D printing method using a mobile liquid interface for faster, continuous polymer component fabrication. This approach overcomes limitations of traditional methods, enabling rapid printing of diverse materials.

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Area of Science:

  • Additive Manufacturing
  • Materials Science
  • Polymer Chemistry

Background:

  • Traditional stereolithography faces limitations in print speed and material compatibility due to adhesive forces and thermal constraints.
  • Existing methods often struggle with continuous fabrication processes, especially for diverse polymer precursors.

Purpose of the Study:

  • To develop a novel stereolithographic three-dimensional printing approach for enhanced fabrication speed and material versatility.
  • To overcome adhesive force limitations and thermal restrictions inherent in conventional 3D printing techniques.

Main Methods:

  • Utilized a mobile liquid interface, specifically a fluorinated oil, to minimize adhesion between the printing interface and the fabricated object.
  • Implemented a continuous cooling mechanism across the entire print area facilitated by the flowing oil, removing thermal limitations.

Main Results:

  • Achieved continuous vertical print rates exceeding 430 millimeters per hour.
  • Demonstrated a volumetric throughput of 100 liters per hour.
  • Successfully printed proof-of-concept structures using hard plastics, ceramic precursors, and elastomers.

Conclusions:

  • The mobile liquid interface stereolithography approach enables significantly faster and continuous 3D printing.
  • This method is versatile, accommodating a wide range of polymeric precursors and material types.
  • The technique removes size restrictions related to thermal management, paving the way for large-scale additive manufacturing.