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3D Printing of Air.

Ibrahim Ozbolat1,2, Deepak Gupta1,2,3, Henrique Piva2,4

  • 1Engineering Science and Mechanics Department, Penn State University; University Park, 16802, USA.

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|November 24, 2025
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Summary

Researchers developed 3D printing using air as an intangible ink to create intricate air channels within materials. This novel technique enables new possibilities across various scientific and engineering fields.

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Area of Science:

  • Materials Science
  • Additive Manufacturing
  • Fluid Dynamics

Background:

  • Traditional 3D printing relies on depositing physical materials to create structures.
  • Existing methods face limitations in creating complex internal geometries and functional voids.

Purpose of the Study:

  • To introduce and explore the novel concept of 3D printing with air as a printable medium.
  • To investigate the dynamics and stability of air bubbles and channels within different materials.

Main Methods:

  • Utilized a 3D printing process to extrude air as an 'ink' into various materials.
  • Studied air bubble formation, deformation, and stability in yield stress fluids.
  • Integrated machine learning for predicting air printability based on material properties.

Main Results:

  • Successfully fabricated freeform 3D air channels with high aspect ratios (~4x10^4) using air as an ink.
  • Demonstrated control over air bubble dynamics and stability within diverse materials.
  • Developed a machine learning framework for rational material selection for air printing.

Conclusions:

  • Air can be effectively utilized as a printable medium for creating complex internal architectures.
  • The findings provide a foundation for novel applications in biology, optics, material science, engineering, and medicine.
  • This technique opens new avenues for designing materials with tailored porosity and functionality.