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Acoustophoretic Liquefaction for 3D Printing Ultrahigh-Viscosity Nanoparticle Suspensions.

Zheng Liu1, Wenyang Pan2, Kaiyang Wang3

  • 1Sibley School of Mechanical and Aerospace Engineering, Cornell University, Ithaca, NY, 14853, USA.

Advanced Materials (Deerfield Beach, Fla.)
|October 3, 2021
PubMed
Summary

Acoustic liquefaction enhances Digital Light Processing (DLP) 3D printing of ultrahigh-viscosity resins. This method enables printing stronger composites with improved resolution and speed.

Keywords:
3D printingfunctional materialspolymer composites

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Area of Science:

  • Materials Science
  • Chemical Engineering
  • Acoustic Engineering

Background:

  • Digital Light Processing (DLP) 3D printing faces limitations with high-viscosity photopolymer resins.
  • Processing ultrahigh-viscosity materials is crucial for creating advanced composites with enhanced mechanical properties.

Purpose of the Study:

  • To introduce and evaluate an acoustic liquefaction approach to enhance resin flow in DLP 3D printing.
  • To enable the processing of ultrahigh-viscosity silica particle-loaded silicone photopolymers.

Main Methods:

  • Utilized acoustic liquefaction to modify the rheological properties of yield stress fluids.
  • Employed numerical simulations to analyze acousto-mechanical coupling and predict flow velocities.
  • Investigated the printing of highly loaded particle suspensions in complex geometries.

Main Results:

  • Achieved processing of resins with apparent viscosity > 3700 Pa s at low shear rates.
  • Predicted and achieved local resin flow velocities exceeding 100 mm s⁻¹.
  • Successfully printed complex geometries using particle suspensions (ϕ = 0.23).
  • Developed composites exhibited 2000% greater tensile toughness compared to neat photopolymer.
  • Demonstrated improvements in printed feature resolution (>25%), printable object size (>50x), and build speed (>3x).

Conclusions:

  • Acoustic liquefaction Digital Light Processing (AL-DLP) significantly enhances the processability of ultrahigh-viscosity resins.
  • AL-DLP offers substantial improvements in resolution, build size, and speed for 3D printing.
  • This technique facilitates the creation of mechanically robust, high-performance 3D printed composites.