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Microliter-Scale Stereolithography Enables High-Resolution 3D Printing of Functional Extraction Sorbents.

Danial Shamsaei1, Indunil U Chandrasekara1, Emma L Katubig1

  • 1Department of Chemistry, Iowa State University, Ames, Iowa 50011,United States.

Analytical Chemistry
|June 9, 2026
PubMed
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This study developed a modified stereolithography (SLA) 3D printing method for creating small-volume extraction sorbents. The new technique enhances the fabrication of solid-phase microextraction (SPME) fibers for analytical applications.

Area of Science:

  • Analytical Chemistry
  • Materials Science
  • 3D Printing Technology

Background:

  • Conventional stereolithography (SLA) 3D printing requires large resin volumes, hindering novel material development in analytical sciences.
  • Developing efficient and low-volume fabrication methods for analytical tools is crucial for advancing sample preparation techniques.

Purpose of the Study:

  • To modify an SLA 3D printing system for fabricating small-diameter extraction sorbents using minimal prepolymer volumes (as low as 150 μL).
  • To compare the performance of SLA and liquid crystal display (LCD) printing for ionic liquid (IL) and deep eutectic solvent (DES)-based sorbents.
  • To evaluate the application of the fabricated sorbent fibers in solid-phase microextraction (SPME) coupled with gas chromatography-mass spectrometry (GC-MS).

Main Methods:

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  • Modification of an SLA 3D printing system to enable low-volume fabrication.
  • Printing of IL and DES-based sorbent mixtures using both SLA and LCD platforms.
  • Characterization of printed sorbents, including physicochemical properties, diameter, mass, and thermogravimetric analysis.
  • Application of polymeric IL fibers for the extraction of 15 analytes from aqueous samples.
  • Gas chromatography-mass spectrometry (GC-MS) analysis with direct thermal desorption.
  • Optimization of extraction parameters (IL content, fiber diameter, kinetics) and method validation.

    • Main Results:

    • The modified SLA approach demonstrated higher printing success rates for extraction sorbents compared to LCD printing.
    • Physicochemical characterization confirmed the properties of the 3D-printed sorbent fibers.
    • The fabricated polymeric IL fibers successfully extracted 15 analytes, including terpenes, polycyclic aromatic hydrocarbons, and alkylphenols.
    • Method validation for terpene extraction showed excellent linearity (R² > 0.967) and low limits of detection (0.05–1.3 μg L⁻¹) and quantification (0.2–4 μg L⁻¹).
    • High fiber-to-fiber reproducibility was confirmed through statistical analysis.

    Conclusions:

    • The modified SLA 3D printing system effectively enables the low-volume fabrication of high-performance SPME fibers.
    • This advancement overcomes a significant barrier in developing novel analytical materials using 3D printing.
    • The developed method offers a promising, reproducible, and efficient approach for sample preparation in analytical chemistry.