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Published on: September 12, 2018
Thermoacoustic Curing Mechanism and Process Optimization in Non-Contact Ultrasonic 3D Printing
Yang Xu1,2, Siqi Yu1,2, Zhiwei Ji1,2
1School of Mechanical and Electrical Engineering, Soochow University, Suzhou 215100, China.
Materials (Basel, Switzerland)
|July 28, 2026
Summary
This study explores ultrasonic three-dimensional (3D) printing, revealing that controlling thermoacoustic curing behavior is key to stable structural formation. Optimized parameters ensure successful material solidification and layer adhesion in additive manufacturing.
Area of Science:
- Materials Science
- Mechanical Engineering
- Acoustic Engineering
Background:
- Non-contact ultrasonic 3D printing offers an alternative to conventional energy-curing methods.
- Limited understanding of ultrasonic curing mechanisms hinders precise control over solidification and structural integrity.
- Developing advanced additive manufacturing techniques requires deeper insights into material behavior during ultrasonic processing.
Purpose of the Study:
- To investigate the thermoacoustic curing behavior of a modified PDMS-based material system using a customized ultrasonic printing platform.
- To establish a multiphysics numerical model for characterizing acoustic pressure, energy distribution, and temperature evolution.
- To provide process guidance for ultrasonic additive manufacturing by optimizing printing parameters.
Main Methods:
- Development of a specialized ultrasonic printing platform for non-contact 3D printing.
- Establishment of a multiphysics numerical model to simulate acoustic and thermal phenomena.
- Systematic experimental validation to quantify the effects of driving power, scanning speed, and line spacing on print quality.
Main Results:
- Solidification is governed by the interplay between acoustic energy confinement and thermal diffusion.
- Optimized parameters (17.5 W, 0.4 mm/s, 0.2-0.25 mm spacing) achieve stable single-track morphology and good interlayer bonding.
- Reciprocating scanning trajectories can lead to thermal accumulation and dimensional deviations.
Conclusions:
- Ultrasonic thermoacoustic curing behavior is understood through the balance of localized energy and thermal diffusion.
- Optimized process parameters enable stable and high-quality structures in ultrasonic additive manufacturing.
- Insights gained offer practical guidance for enhancing ultrasonic 3D printing processes for specific material systems.
