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Related Experiment Video

Updated: Sep 13, 2025

Solvent Bonding for Fabrication of PMMA and COP Microfluidic Devices
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Solvent-Rich Pre-Coagulation Bath for Tunable Liquid-State Fusion Enables Robust Two-Step Polymer Embedded Printing.

Kaidong Song1, Qian Wu2, Ashley M Compaan3

  • 1Department of Mechanical and Aerospace Engineering, University of Florida, Gainesville, FL, 32611, USA.

Advanced Science (Weinheim, Baden-Wurttemberg, Germany)
|July 28, 2025
PubMed
Summary

A novel room-temperature 3D printing method, immersion phase separation-embedded 3D printing (IPS-E3DP), enables effective polymer fusion without heat or binders. This technique allows for high-fidelity printing of complex engineering polymer structures.

Keywords:
embedded 3D printingengineering polymersimmersion phase separationliquid‐state fusionsolvent‐rich support bath

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Area of Science:

  • Materials Science
  • Polymer Chemistry
  • Additive Manufacturing

Background:

  • Traditional 3D printing of engineering polymers often relies on heat or binders, leading to issues like residual stress, warpage, and impurities.
  • Effective interlayer fusion is crucial for achieving robust and functional 3D printed parts.

Purpose of the Study:

  • To introduce a novel room-temperature polymer fusion and solidification approach for self-supported engineering polymer printing.
  • To overcome the limitations of heat-enabled or binder-based fusion methods in 3D printing.

Main Methods:

  • The study presents immersion phase separation-embedded 3D printing (IPS-E3DP), a two-step process involving a solvent-rich pre-coagulation support bath and a non-solvent coagulation bath.
  • Polymer inks are deposited in a yield-stress support bath, allowing for liquid-state fusion and shape retention before complete solidification.

Main Results:

  • IPS-E3DP enables self-supported, room-temperature, high-fidelity printing of diverse engineering polymers, blends, and composites.
  • The process facilitates superior geometric complexity and avoids thermal stress, warpage, and impurities associated with conventional methods.
  • The approach can be adapted for polymer binder-based printing, enhancing material versatility.

Conclusions:

  • IPS-E3DP offers a promising alternative for 3D printing engineering polymers at room temperature, enhancing fusion quality and geometric freedom.
  • This method addresses key challenges in additive manufacturing, paving the way for advanced polymer part fabrication.
  • The technique demonstrates significant potential for printing complex structures with high precision and material integrity.