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Dual-Wavelength Simultaneous Patterning of Degradable Thermoset Supports for One-Pot Embedded 3D Printing
Isabel Arias Ponce1,2, Bryan Moran2, Craig J Hawker1,3,4
1Materials Department, University of California Santa Barbara, Santa Barbara, California 93106, United States.
ACS Central Science
|June 30, 2025
Summary
This study introduces a new base-degradable thermoset for 3D printing sacrificial supports. This method enables complex geometries using dual-wavelength 3D printing and easy support removal.
Area of Science:
- Materials Science
- Polymer Chemistry
- Additive Manufacturing
Background:
- Vat photopolymerization (VP) allows high-precision, fast 3D printing of complex shapes.
- Unsupported features in VP printing often require manual support removal, limiting design freedom.
- Dissolvable sacrificial supports offer an attractive alternative for automated support removal.
Purpose of the Study:
- To develop a base-degradable thermoset for sacrificial supports in VP 3D printing.
- To enable simultaneous printing of structural components and dissolvable supports.
- To expand the range of achievable 3D printed geometries and materials.
Main Methods:
- A one-pot formulation combining a structural material and a base-degradable thermoset was developed.
- A dual-wavelength negative imaging (DWNI) Digital Light Processing (DLP) printer was used.
- Visible light patterned the degradable supports, while UV light cured the permanent network simultaneously using a single DMD.
Main Results:
- The DWNI DLP printer successfully patterned base-degradable thermoset supports alongside the primary material.
- Thermal postprocessing enhanced the final conversion of the primary material.
- Supports were efficiently degraded in a basic, aqueous solution, leaving the primary object intact.
Conclusions:
- This approach provides a robust method for dual-wavelength patterning of sacrificial thermoset supports.
- The developed technique broadens the scope of accessible 3D printable materials and complex geometries.
- This innovation simplifies post-processing and enhances design flexibility in VP 3D printing.
