Researchers at the University of California Santa Barbara and the Lawrence Livermore National Laboratory (LLNL) have developed a revolutionary 3D printing technique that creates two materials from a resin, which means that additive production can remove the need for manual support. The breakthrough published in the ACS Central Science shows a single photorative resin, which at the same time produces solid objects and resolving structural supports, depending on the type of light load during printing.
The innovative approach deals with one of the most challenging aspects of VAT photolymerization of time-consuming and frequently nerve-wracking process of manual removal of temporary supports from complicated structures. By activating two materials from a resin through selective light load, the research team has opened new possibilities for complex 3D printed applications, including Tissue Engineering scaffolding, mechanical compounds and hinges.
Dual-light system for two materials from a resin
The research team under the direction of the corresponding author Maxim Shustff developed a specialized 3D printer, which runs out both ultraviolet and visible light, which at the same time enables permanent objects and their temporary support. This dual-light approach is a significant progress of VAT photolymerization technology, which is known for its speed and high-resolution skills.
“VAT photolymerization is known for the fast and high-resolution pressure, but one of the most nerve-wracking parts after printing is manual removal of supports for complicated locking and overhang structures. We are very pleased that we can use simple chemistry to solve this problem.”
– Maxim Shusteff, one of the authors of the research work
The key innovation lies in the formulation of a single resin that contains different monomers that react to certain light wavelengths. In the event of visible light, acrylic monomers solidify in the resin, water -based support materials. Under the exposure of UV light, epoxy monomers harden in the permanent part of the object and generate two significantly different materials than a resin system.
This selective polymerization process eliminates the conventional two -stage approach, in which objects for support structures have to be immersed in separate resin characters. The conventional method adds time, costs and complexity due to additional material requirements and manual effort that is required to remove temporary supports.
Innovative chemistry and safe resolution process
The research team, including co-researcher Sijia Huang, formulated its breakthrough resin by mixing various components such as acrylate/methacrylate and epoxy monomers together with photorative substances that absorb both visible and UV light. This careful chemical composition enables the selective formation of two materials from a resin through controlled light load.
During the tests, the researchers observed different material behavior under different lighting conditions. The acrylic monomers reacted exclusively to visible light and formed the dissolvable support structures, while epoxy monomers only hardened under UV light and generate the permanent object components. This wavelength -specific reaction is crucial in order to achieve precise control, through which parts of the pressure become temporarily temporary.
The resolution process for removing support structures turned out to be both efficiently and environmentally friendly. The researchers simply placed complete objects in a sodium hydroxide solution at room temperature and reveal the permanent structures within 15 minutes. It is important that the scaffolding was broken down into non -toxic connections and take into account safety concerns in connection with traditional support removal methods.
Complex structures demonstrate technological potential
In order to validate their approach to creating two materials from a resin, the research team produced increasingly complex demonstration structures. This included a chessboard pattern, a cross design, interlocking rings, a ball included in a cage and two balls arranged in a helical configuration.
These test structures show the ability of technology to create complicated geometries that would be challenging or impossible through traditional manufacturing methods. The ability to print complex interlocking components in a single operation with supports that dissolve cleanly opens up new possibilities for mechanical assemblies, artistic creations and functional devices.
The successful creation of these demonstration pieces validates that two materials from a resin can effectively replace traditional multi-step printing processes. This progress could significantly expand the scope for 3D printed objects, especially in areas that require complex internal structures or moving parts.
Implications for advanced manufacturing applications
The breakthrough in the production of two materials from a resin is a special promise for tissue engineering applications in which biodegradable scaffolding must support cell growth and at the same time dissolve harmlessly in the body. The technology could enable the creation of complex tissue fans with integrated support structures that dissolve in controlled installments.
Mechanical applications, including joints, hinges and other moving assemblies, can benefit from the ability to print fully functional mechanisms in a single operation. The conventional production of such components often requires the assembly of several parts, while this approach can generate mechanical systems directly from the printer.
Research represents a significant step for more efficient and versatile additive manufacturing processes and may reduce the production times and costs and expand the complexity of achievable designs.
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