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Stability of High Speed 3D Printing in Liquid-Like Solids.

Kyle J LeBlanc1, Sean R Niemi1, Alexander I Bennett1

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ACS Biomaterials Science & Engineering
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High-speed 3D printing in microgel media overcomes fluid instabilities. Researchers identified viscosity

Keywords:
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Area of Science:

  • Materials Science
  • Fluid Dynamics
  • Additive Manufacturing

Background:

  • Fluid instabilities, such as surface tension and body forces, hinder shape fidelity in conventional 3D printing as inks solidify.
  • Printing within jammed granular microgels circumvents these issues by eliminating surface tension and body forces, enabling stable structures.
  • High-speed printing in microgels may introduce inertial instabilities, potentially disrupting printed features due to turbulence.

Purpose of the Study:

  • To design and test a high-speed 3D printing system capable of operating at 1 m/s nozzle translation speed.
  • To identify and characterize fluid instabilities that emerge during high-speed additive manufacturing in granular microgel media.
  • To investigate the influence of material viscosity on printing stability at high velocities.

Main Methods:

  • Development of a specialized experimental setup for high-speed (1 m/s) 3D printing.
  • Printing into a continuum of jammed granular microgels.
  • Systematic variation of injected material viscosity to assess its effect on stability.

Main Results:

  • The viscosity of the injected material was found to effectively control the onset of the Reynolds instability.
  • An unexpected, previously uncharacterized instability was observed near the upper surface of the granular microgel medium.
  • High-speed printing at 1 m/s is feasible, but requires careful management of inertial effects.

Conclusions:

  • High-speed 3D printing in granular microgels offers a promising route to creating complex structures by mitigating traditional fluid instabilities.
  • Material viscosity is a critical parameter for controlling Reynolds instability in this printing regime.
  • Further research is needed to understand and mitigate the newly discovered instability for optimized high-speed printing.