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Highly Expandable Foam for Lithographic 3D Printing.

David M Wirth1, Anna Jaquez1, Sofia Gandarilla1

  • 1Department of NanoEngineering, University of California San Diego, Jacobs School of Engineering, La Jolla, California 92093, United States.

ACS Applied Materials & Interfaces
|April 9, 2020
PubMed
Summary
This summary is machine-generated.

A new foaming resin for 3D printing allows parts to expand 40x post-printing, overcoming size limitations in additive manufacturing for complex, large-scale structures.

Keywords:
3D printingadditive manufacturingdigital light processingfoamshigh expansion

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Area of Science:

  • Materials Science
  • Manufacturing Engineering
  • Polymer Chemistry

Background:

  • Additive manufacturing (AM) typically produces parts smaller than the machine.
  • Current methods involve post-processing and assembly to create larger structures.
  • This limits the scale and complexity of AM-fabricated components.

Purpose of the Study:

  • To develop a novel foaming prepolymer resin for lithographic AM.
  • To enable the post-printing expansion of 3D-printed parts to significantly larger volumes.
  • To overcome the inherent build volume limitations of AM machines.

Main Methods:

  • Comprehensive screening of resin formulations for foaming properties.
  • Detailed analysis of printing parameters for lithographic AM of the resin.
  • Characterization of the mechanical properties of the expanded, 3D-printed foams.

Main Results:

  • Successful development of a foaming prepolymer resin.
  • Demonstrated post-printing expansion of parts up to 40x their original volume.
  • Fabrication of complex, porous foam structures exceeding typical AM build volumes.

Conclusions:

  • The developed foaming resin enables the production of large-scale AM parts.
  • This technology overcomes critical size limitations in additive manufacturing.
  • Potential applications exist in architecture, aerospace, energy, and biomedicine due to complex foam geometries.