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Rapid High-Resolution Visible Light 3D Printing.

Dowon Ahn1, Lynn M Stevens1, Kevin Zhou1

  • 1Department of Chemistry, The University of Texas at Austin, 105 East 24th Street, Stop A5300, Austin, Texas 78712, United States.

ACS Central Science
|October 1, 2020
PubMed
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Researchers developed rapid, high-resolution 3D printing using visible light by creating new photopolymer resins. This overcomes limitations of UV light, enabling advanced material printing with improved speed and resolution.

Area of Science:

  • Additive Manufacturing
  • Photochemistry
  • Polymer Science

Background:

  • Traditional UV/violet light 3D printing offers high speed and resolution but is limited by material degradation and light attenuation.
  • Visible light photochemistry is slower and less efficient, hindering its application in additive manufacturing.

Purpose of the Study:

  • To develop a rapid and high-resolution 3D printing method using visible light.
  • To overcome the slow reaction kinetics and resolution limitations of visible light photocuring.
  • To expand the scope of 3D printable materials beyond UV-curable resins.

Main Methods:

  • Development of novel panchromatic photopolymer resins utilizing electron-deficient and electron-rich coinitiators.
  • Incorporation of azo-dyes into resins to confine curing to irradiation zones and enhance spatial resolution.

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  • Implementation of a screening method for optimizing resin composition, exposure time, and azo-dye loading.
  • Main Results:

    • Achieved rapid, high-resolution 3D printing with visible light, rivaling UV-based technologies.
    • Demonstrated the critical role of coinitiators in accelerating visible light photocuring.
    • Showcased the ability to print stiff and soft objects with feature sizes below 100 μm at speeds up to 45 mm/h.
    • Attained mechanical isotropy in printed objects.

    Conclusions:

    • A versatile visible-light-based 3D printing method was established, overcoming previous speed and resolution limitations.
    • The developed photopolymer resins and printing strategy enable the fabrication of complex objects with fine features and desirable mechanical properties.
    • This technology provides a foundation for future advancements in bio-printing and composite 3D printing.