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Multiscale 3D printing via active nozzle size and shape control.

Seok Won Kang1, Jochen Mueller1

  • 1Department of Civil and Systems Engineering, Johns Hopkins University, Baltimore, MD, USA.

Science Advances
|June 5, 2024
PubMed
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This summary is machine-generated.

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Adaptive nozzle 3D printing (AN3DP) dynamically changes nozzle size for high resolution and speed. This innovation enables printing complex multiscale architectures and advanced bioprinted implants.

Area of Science:

  • Materials Science
  • Mechanical Engineering
  • Biomedical Engineering

Background:

  • Traditional 3D printing faces a resolution-speed trade-off due to fixed nozzle diameters.
  • This limitation hinders the fabrication of multiscale architectures with both bulk and intricate features.

Purpose of the Study:

  • To introduce adaptive nozzle 3D printing (AN3DP) for dynamic nozzle diameter and shape control.
  • To overcome the resolution-speed conflict in extrusion-based 3D printing.

Main Methods:

  • Developed an AN3DP system with eight controllable, tendon-driven pins around a flexible membrane.
  • Optimized nozzle design for shear-thinning inks and constrained-space printing (conformal, embedded).

Main Results:

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  • Demonstrated fabrication of components with continuous gradients, avoiding discretization.
  • Achieved enhanced density and contour precision compared to conventional 3D printing.
  • Successfully printed cell-laden and hierarchical implants with bone-like microarchitecture.

Conclusions:

  • AN3DP significantly expands the capabilities of extrusion-based 3D printing.
  • The technology facilitates diverse applications, including advanced bioprinting.
  • AN3DP enables the creation of complex, high-precision structures previously unattainable.