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Overprinting with tomographic volumetric additive manufacturing.

Felix Wechsler¹, Viola Sgarminato^2,3, Riccardo Rizzo²

¹Laboratory of Applied Photonics Devices, École polytechnique fédérale de Lausanne (EPFL), Lausanne, Switzerland. overprinting@felixwechsler.science.

Nature Communications

|June 8, 2026

Summary

Tomographic Volumetric Additive Manufacturing (TVAM) enables rapid 3D printing of complex objects. This study optimizes projection patterns for overprinting diverse materials, overcoming challenges with occlusions and varied optical properties.

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Area of Science:

Additive Manufacturing
Optical Engineering
Computational Imaging

Background:

Tomographic Volumetric Additive Manufacturing (TVAM) is a fast, light-based 3D printing method.
Calculating projection patterns for TVAM is challenging with occlusions and varied material optical properties (refractive index, scattering).

Purpose of the Study:

To demonstrate and optimize TVAM overprinting scenarios with diverse materials and geometries.
To develop a physically based, differentiable ray-optics approach for projection pattern calculation.

Main Methods:

Utilized an open-source framework (Dr.TVAM) for differentiable, physically based ray-optics simulations.
Performed simulations and experimental verifications for overprinting absorbing, refracting, reflecting, and scattering elements.
Tested scenarios in both round and square vials with various optical properties.

Main Results:

Successfully demonstrated overprinting of new structures onto/around pre-existing components made from different materials.
Achieved high-quality projections for laser and LED illumination within minutes, and lower-quality projections within seconds.
Validated the approach through experimental verification across multiple complex scenarios.

Conclusions:

The developed differentiable, physically based ray-optics approach effectively optimizes TVAM projection patterns for complex overprinting scenarios.
The Dr.TVAM framework offers superior speed, flexibility, and quality compared to existing open-source solutions for TVAM.
This work advances TVAM capabilities for fabricating objects with diverse optical properties and integrated components.