One-step volumetric additive manufacturing of complex polymer structures

Shusteff, Maxim; Browar, Allison E.; Kelly, Brett; Henriksson, Johannes; Weisgraber, Todd H.; Panas, Robert M.; Fang, Nicholas X.; Spadaccini, Christopher M.

doi:10.1126/sciadv.aao5496

Cited by 268 publications

(209 citation statements)

References 42 publications

(46 reference statements)

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“…Another notable recent method which aims to tackle the speed‐associated concerns regarding 3D printing and has achieved promising results is the Volumetric AM (VAM) technique . VAM could fabricate complex millimeter scale 3D polymeric geometries in the span of a few seconds without any supporting structures.…”

Section: Fabrication Methods: Advantages and Challengesmentioning

confidence: 99%

Mechanical Metamaterials and Their Engineering Applications

et al. 2019

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In the past decade, mechanical metamaterials have garnered increasing attention owing to its novel design principles which combine the concept of hierarchical architecture with material size effects at micro/nanoscale. This strategy is demonstrated to exhibit superior mechanical performance that allows us to colonize unexplored regions in the material property space, including ultrahigh strength-to-density ratios, extraordinary resilience, and energy absorption capabilities with brittle constituents. In the recent years, metamaterials with unprecedented mechanical behaviors such as negative Poisson's ratio, twisting under uniaxial forces, and negative thermal expansion are also realized. This paves a new pathway for a wide variety of multifunctional applications, for example, in energy storage, biomedical, acoustics, photonics, and thermal management. Herein, the fundamental scientific theories behind this class of novel metamaterials, along with their fabrication techniques and potential engineering applications beyond mechanics are reviewed. Explored examples include the recent progresses for both mechanical and functional applications. Finally, the current challenges and future developments in this emerging field is discussed as well.

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Section: Fabrication Methods: Advantages and Challengesmentioning

confidence: 99%

Mechanical Metamaterials and Their Engineering Applications

et al. 2019

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“…Further innovations on DLP such as continuous building in the z ‐dimension allow achieving a printing speed far exceeding any other methods . Recent attempt on direct forming 3D object in a volumetric fashion forgoes even the layer‐wise printing, but the technique has yet to evolve into the mainstream . Generally, DLP employs light curable liquid resins.…”

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confidence: 99%

Rapid Open‐Air Digital Light 3D Printing of Thermoplastic Polymer

et al. 2019

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printing is, however, limited by various factors, with printing speed and material versatility being the most decisive. From the standpoint of printing speed, layerwise printing by digital light processing (DLP) offers significant inherent advantage over point-wise printing by most other methods such as fused deposition modeling (FDM) and stereolithography (SLA). [20] Further innovations on DLP such as continuous building in the z-dimension allow achieving a printing speed far exceeding any other methods. [21][22][23] Recent attempt on direct forming 3D object in a volumetric fashion forgoes even the layer-wise printing, but the technique has yet to evolve into the mainstream. [24,25] Generally, DLP employs light curable liquid resins. Upon digital light exposure, the resin cross-links and forms a thermoset polymer that ensures its separation from the surrounding liquid precursors. This rapid liquid-solid separation is the key enabling characteristic for DLP. Although cross-linking ensures such, the resulting thermoset polymers cannot be reprocessed. This prohibits its broader utility in situations that require further processing of the printed materials. In principle, this limitation can be overcome if the DLP processing can be extended to reprocessable thermoplastic polymers. Although light curable thermoplastic polymers are known, meeting the unique DLP requirement for rapid separation between the liquid monomer and the un-crosslinked polymer is not straightforward because of their intrinsic good miscibility. Hereafter, we describe our successful attempt in DLP printing of a thermoplastic polymer and lay out key enabling factors for such a process. We further illustrate that the water dissolvable nature of the resulting polymer is advantageous in making various multifunctional 3D structures. We find that the oxygen naturally present in ambient air can inhibit the light curing process. This effect can be utilized to achieve rapid open-air printing without the complex interfacial engineering typically required for fast DLP printing methods. [21][22][23] We hypothesize that two key factors should be carefully considered for DLP printing of thermoplastic polymers (Figure 1a). Herein, two concurrent and competing processes occur: 1) the polymerization and 2) the diffusion/dissolution of the polymer into the surrounding uncured liquid monomer. Rapid liquidsolid separation is possible only if the first process dominates 3D printing has witnessed a new era in which highly complexed customized products become reality. Realizing its ultimate potential requires simultaneous attainment of both printing speed and product versatility. Among various printing techniques, digital light processing (DLP) stands out in its high speed but is limited to intractable light curable thermosets. Thermoplastic polymers, despite their reprocessibility that allows more options for further manipulation, are restricted to intrinsically slow printing methods such as fused deposition modeling. Extending DLP to thermoplastics is highly desirabl...

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“…The results indicate that low-absorbing resins containing ~0.1% photoinitiator, illuminated at modest powers (~10-100 mW), may be successfully used to build full structures in ~1-10' [7].…”

Section: Volumetric 3d Printingmentioning

confidence: 98%

The Evolution of 3D Printing in AEC: From Experimental to Consolidated Techniques

Paoletti¹,

Ceccon²

2018

3D Printing

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The chapter leads the reader through the historical development of additive manufacturing (AM) techniques until the most recent developments. A tentative taxonomy is added to the historical perspective, in order to better understand the main lines of development and the potential cross-fertilization opportunities. Some case studies are analyzed in order to provide a clearer picture of the practical applications of AM in architecture engineering and construction (AEC), with a particular attention to the use of AM for final products rather than just prototypes. Eventually, some thoughts are shared as to the impact of AM on AEC beyond the mere cost-effectiveness and well into the potential change of paradigms in how architecture can be thought of and further developed embracing the new world of opportunities brought by AM.

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One-step volumetric additive manufacturing of complex polymer structures

Abstract: A new approach for ultrarapid 3D manufacturing creates complex aperiodic volumes in a single step.

Cited by 268 publications

References 42 publications

Mechanical Metamaterials and Their Engineering Applications

Mechanical Metamaterials and Their Engineering Applications

Rapid Open‐Air Digital Light 3D Printing of Thermoplastic Polymer

The Evolution of 3D Printing in AEC: From Experimental to Consolidated Techniques

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