Hybrid Formative-Additive Manufacturing

Material extrusion additive manufacturing (AM) provides extensive design flexibility and exceptional material versatility, enabling the fabrication of complex, multifunctional objects ranging from embedded electronics to soft robotics and vascularized tissues. The bottom-up creation of these objects typically requires discretization into layers and voxels. However, the voxel size, determined by the nozzle diameter, limits extrusion rate, creating a conflict between resolution and speed. To address these inherent scalability challenges, the study proposes a hybrid formative-additive manufacturing technology that combines the respective strengths of each method-speed and quality with complexity and flexibility. The approach involves 3D-printing complex geometries, multimaterial features, and bounding walls of bulky, lower-resolution volumes, which are rapidly filled via casting or molding. By precisely controlling the materials' rheological properties-while maintaining similar solidified properties and high interfacial strength-several typical AM flaws, such as bulging and internal voids, are eliminated, achieving exponentially faster production speeds for objects with varying feature sizes.