Rotational multimaterial printing of filaments with subvoxel control

Area of Science:

• Materials Science and Engineering
• Additive Manufacturing
• Bioinspired Materials

Background:

• Helical structures in nature exhibit unique mechanical properties and multifunctionality.
• Existing synthetic methods for helical architectures lack simultaneous multimaterial patterning and subvoxel control.
• Previous 3D printing approaches have addressed multimaterial or rotational capabilities separately, but not integrated them.

Purpose of the Study:

• To develop a novel fabrication platform for creating multimaterial, helically architected filaments with subvoxel control.
• To enable the precise patterning of materials within helical structures for advanced functionalities.
• To demonstrate the platform's capability in fabricating functional devices and hierarchical lattices.

Main Methods:

• Development of a rotational multimaterial 3D printing (RM-3DP) platform.
• Utilizing a continuously rotating multimaterial nozzle with controlled angular-to-translational velocity.
• Achieving subvoxel control over local orientation and material composition in helical filaments.

Main Results:

• Successful fabrication of helical filaments with programmable helix angle, layer thickness, and interfacial area.
• Creation of functional artificial muscles using helical dielectric elastomer actuators with embedded conductive channels.
• Fabrication of hierarchical lattices with architected helical struts incorporating stiff springs within a compliant matrix.

Conclusions:

• The RM-3DP platform offers unprecedented control over the design and fabrication of complex helical architectures.
• This additive manufacturing approach enables the creation of multifunctional architected matter with bioinspired motifs.
• The technology opens new possibilities for designing advanced materials with tailored mechanical and functional properties.