Stiffness control in dual color tomographic volumetric 3D printing

Holographic direct sound printing

Direct sound printing (DSP), an alternative additive manufacturing process driven by sonochemical polymerization, has traditionally been confined to a single acoustic focal region, resulting in a voxel-by-voxel printing approach. To overcome this limitation, we introduce holographic direct sound printing (HDSP), where acoustic holograms, storing cross-sectional images of the desired parts, pattern acoustic waves to induce regional cavitation bubbles and on-demand regional polymerization. HDSP outperforms DSP in terms of printing speed by one order of magnitude and yields layerless printed structures. In our HDSP implementation, the hologram remains stationary while the printing platform moves along a three-dimensional path using a robotic arm. We present sono-chemiluminescence and high-speed imaging experiments to thoroughly investigate HDSP and demonstrate its versatility in applications such as remote ex-vivo in-body printing and complex robot trajectory planning. We showcase multi-object and multi-material printing and provide a comprehensive process characterization, including the effects of hologram design and manufacturing on the HDSP process, polymerization progression tracking, porosity tuning, and robotic trajectory computation. Our HDSP method establishes the integration of acoustic holography in DSP and related applications.

Light from Afield: Fast, High-Resolution, and Layer-Free Deep Vat 3D Printing

Harnessing light for cross-linking of photoresponsive materials has revolutionized the field of 3D printing. A wide variety of techniques leveraging broad-spectrum light shaping have been introduced as a way to achieve fast and high-resolution printing, with applications ranging from simple prototypes to biomimetic engineered tissues for regenerative medicine. Conventional light-based printing techniques use cross-linking of material in a layer-by-layer fashion to produce complex parts. Only recently, new techniques have emerged which deploy multidirection, tomographic, light-sheet or filamented light-based image projections deep into the volume of resin-filled vat for photoinitiation and cross-linking. These Deep Vat printing (DVP) approaches alleviate the need for layer-wise printing and enable unprecedented fabrication speeds (within a few seconds) with high resolution (>10 μm). Here, we elucidate the physics and chemistry of these processes, their commonalities and differences, as well as their emerging applications in biomedical and non-biomedical fields. Importantly, we highlight their limitations, and future scope of research that will improve the scalability and applicability of these DVP techniques in a wide variety of engineering and regenerative medicine applications.

Bioinspired Suspended Sensing Membrane Array with Modulable Wedged-Conductive Channels for Crosstalk-Free and High-Resolution Detection

High spatial-resolution detection is essential for biomedical applications and human-machine interaction. However, as the sensor array density increases, the miniaturization will lead to interference between adjacent units and deterioration in sensing performance. Here, inspired by the cochlea's sensing structure, a high-density flexible pressure sensor array featuring with suspended sensing membrane with sensitivity-enhanced customized channels is presented for crosstalk-free and high-resolution detection. By imitating the basilar membrane attached to spiral ligaments, a sensing membrane is fixed onto a high-stiffness substrate with cavities, forming a stable braced isolation to provide an excellent crosstalk-free capability (crosstalk coefficient: 47.24 dB) with high-density integration (100 units within 1 cm2). Similar to the opening of ion channels in hair cells, the wedge-type expansion of the embedded cracks introduced by stress concentration structures enables a high sensitivity (0.19 kPa-1) and a large measuring range (400 kPa). Finally, it demonstrates promising applications in distributed displays and the condition monitoring of medical-surgical intubation.

Multi-color dual wavelength vat photopolymerization 3D printing via spatially controlled acidity

Dual wavelength vat photopolymerization (DW-VP) has emerged as a powerful approach to create multimaterial objects. However, only a limited range of properties have been showcased. In this work, we report the 3D printing (3DP) of multi-color objects from a single resin vat using DW-VP. This was accomplished by concurrently curing resin with visible light and modulating local resin color with 365-nm ultraviolet (UV) light. The key advance was to use a photoacid generator (PAG) in combination with pH responsive dyes in the 3DP resins. The specific color is dictated by the extent of reaction, or local acidity in our case, and controlled by the light dosage and pattern of UV light applied. Multi-color object formation was implemented in two-step processes involving first 3DP to set the object structure, followed by UV exposure, as well as single processes that leveraged DW-VP to create a broad range of vibrant colors and patterns.

Glycerol-based sustainably sourced resin for volumetric printing

Volumetric Additive Manufacturing (VAM) represents a revolutionary advancement in the field of Additive Manufacturing, as it allows for the creation of objects in a single, cohesive process, rather than in a layer-by-layer approach. This innovative technique offers unparalleled design freedom and significantly reduces printing times. A current limitation of VAM is the availability of suitable resins with the required photoreactive chemistry and from sustainable sources. To support the application of this technology, we have developed a sustainable resin based on polyglycerol, a bioderived (e.g., vegetable origin), colourless, and easily functionisable oligomer produced from glycerol. To transform polyglycerol-6 into an acrylate photo-printable resin we adopted a simple, one-step, and scalable synthesis route. Polyglycerol-6-acrylate fulfils all the necessary criteria for volumetric printing (transparency, photo-reactivity, viscosity) and was successfully used to print a variety of models with intricate geometries and good resolution. The waste resin was found to be reusable with minimal performance issues, improving resin utilisation and minimising waste material. Furthermore, by incorporating dopants such as poly(glycerol) adipate acrylate (PGA-A) and 10,12-pentacosadyinoic acid (PCDA), we demonstrated the ability to print objects with a diverse range of functionalities, including temperature sensing probes and a polyester excipient, highlighting the potential applications of these new resins.

Continuous Volumetric 3D Printing: Xolography in Flow

Additive manufacturing techniques continue to improve in resolution, geometrical freedom, and production rates, expanding their application range in research and industry. Most established techniques, however, are based on layer-by-layer polymerization processes, leading to an inherent trade-off between resolution and printing speed. Volumetric 3D printing enables the polymerization of freely defined volumes allowing the fabrication of complex geometries at drastically increased production rates and high resolutions, marking the next chapter in light-based additive manufacturing. This work advances the volumetric 3D printing technique xolography to a continuous process. Dual-color photopolymerization is performed in a continuously flowing resin, inside a tailored flow cell. Supported by simulations, the flow profile in the printing area is flattened, and resin velocities at the flow cell walls are increased to minimize unwanted polymerization via laser sheet-induced curing. Various objects are printed continuously and true to shape with smooth surfaces. Parallel object printing paves the way for up-scaling the continuous production, currently reaching production rates up to 1.75 mm3  s-1 for the presented flow cell. Xolography in flow provides a new opportunity for scaling up volumetric 3D printing with the potential to resolve the trade-off between high production rates and high resolution in light-based additive manufacturing.

Advances in volumetric bioprinting

The three-dimensional (3D) bioprinting technologies are suitable for biomedical applications owing to their ability to manufacture complex and high-precision tissue constructs. However, the slow printing speed of current layer-by-layer (bio)printing modality is the major limitation in biofabrication field. To overcome this issue, volumetric bioprinting (VBP) is developed. VBP changes the layer-wise operation of conventional devices, permitting the creation of geometrically complex, centimeter-scale constructs in tens of seconds. VBP is the next step onward from sequential biofabrication methods, opening new avenues for fast additive manufacturing in the fields of tissue engineering, regenerative medicine, personalized drug testing, and soft robotics, etc. Therefore, this review introduces the printing principles and hardware designs of VBP-based techniques; then focuses on the recent advances in VBP-based (bio)inks and their biomedical applications. Lastly, the current limitations of VBP are discussed together with future direction of research.

Colorful 3D Printing: A Critical Feasibility Analysis of Multi-Wavelength Additive Manufacturing

Employing two colors of light to 3D print objects holds potential for accessing advanced printing modes, such as the generation of multi-material objects from a single print. Thus, dual-wavelength-driven photoreactive systems (reactions that require or utilize two wavelengths) and their exploitation as chemo-technological solutions for additive manufacturing technologies have experienced considerable development over the last few years. Such systems saw an increase in printing speeds, a decrease in resolution thresholds, and─perhaps most importantly─the actual generation of multi-material objects. However, the pace at which such reactive systems are developed is moderate and varies significantly depending on the fashion in which the two colors of light are employed. Herein, we address for the first time the varying logic conjugations of light-activated chemical compounds in dual-wavelength photochemical processes in a systematic manner and consider their implications from a photochemical point of view. To date, four dual-wavelength reaction types have been reported, termed synergistic (λ1 AND λ2), antagonistic (reversed λ1 AND λ2), orthogonal (λ1 OR λ2), and─most recently─cooperative (λ1 AND λ2 or λ1 OR λ2). The progress of their implementation in additive manufacturing is assessed individually, and their concurrent and individual chemical challenges are identified. These challenges need to be addressed for future dual-wavelength photochemical systems to progress multi-wavelength additive manufacturing technologies beyond their current limitations.

Synergizing Algorithmic Design, Photoclick Chemistry and Multi-Material Volumetric Printing for Accelerating Complex Shape Engineering

The field of biomedical design and manufacturing has been rapidly evolving, with implants and grafts featuring complex 3D design constraints and materials distributions. By combining a new coding-based design and modeling approach with high-throughput volumetric printing, a new approach is demonstrated to transform the way complex shapes are designed and fabricated for biomedical applications. Here, an algorithmic voxel-based approach is used that can rapidly generate a large design library of porous structures, auxetic meshes and cylinders, or perfusable constructs. By deploying finite cell modeling within the algorithmic design framework, large arrays of selected auxetic designs can be computationally modeled. Finally, the design schemes are used in conjunction with new approaches for multi-material volumetric printing based on thiol-ene photoclick chemistry to rapidly fabricate complex heterogeneous shapes. Collectively, the new design, modeling and fabrication techniques can be used toward a wide spectrum of products such as actuators, biomedical implants and grafts, or tissue and disease models.

Deconvolution volumetric additive manufacturing

Volumetric additive manufacturing techniques are a promising pathway to ultra-rapid light-based 3D fabrication. Their widespread adoption, however, demands significant improvement in print fidelity. Currently, volumetric additive manufacturing prints suffer from systematic undercuring of fine features, making it impossible to print objects containing a wide range of feature sizes, precluding effective adoption in many applications. Here, we uncover the reason for this limitation: light dose spread in the resin due to chemical diffusion and optical blurring, which becomes significant for features ⪅0.5 mm. We develop a model that quantitatively predicts the variation of print time with feature size and demonstrate a deconvolution method to correct for this error. This enables prints previously beyond the capabilities of volumetric additive manufacturing, such as a complex gyroid structure with variable thickness and a fine-toothed gear. These results position volumetric additive manufacturing as a mature 3D printing method, all but eliminating the gap to industry-standard print fidelity.

Versatile volumetric additive manufacturing with 3D ray tracing

Tomographic volumetric additive manufacturing (VAM) is an optical 3D printing technique where an object is formed by photopolymerizing resin via tomographic projections. Currently, these projections are calculated using the Radon transform from computed tomography but it ignores two fundamental properties of real optical projection systems: finite etendue and non-telecentricity. In this work, we introduce 3D ray tracing as a new method of computing projections in tomographic VAM and demonstrate high fidelity printing in non-telecentric and higher etendue systems, leading to a 3x increase in vertical build volume than the standard Radon method. The method introduced here expands the possible tomographic VAM printing configurations, enabling faster, cheaper, and higher fidelity printing.

Multi-Jet Fusion 3D Voxel Printing of Conductive Elastomers

3D voxel printing enables the fabrication of parts with site-specific materials and properties at voxel-scale resolution, while the current research mainly focuses on the variations in mechanical properties and colors. In this work, the design and fabrication of voxelated conductive elastomers using Multi Jet Fusion 3D voxel printing actualized by a newly developed multifunctional agent (MA) are investigated. The MA, mainly consisting of carbon nanotubes and poly(3,4-ethylenedioxythiophene) polystyrene sulfonate, serves as an infrared-absorbing colorant, a reinforcement, and a conductive filler simultaneously. By controlling the drop-on-demand dispensing of the agents on thermoplastic polyurethane powder, the electrical conductivity across a single printed part can be tailored over a wide range from 10^-10 to 10^-1 S cm^-1 at a voxel resolution of ≈100 µm. Assembly-free strain sensors comprising conductive sensing layers and insulating frames are fabricated to demonstrate the capability of the technique in manufacturing all-printed wearable devices.

Advances in Translational 3D Printing for Cartilage, Bone, and Osteochondral Tissue Engineering

The regeneration of 3D tissue constructs with clinically relevant sizes, structures, and hierarchical organizations for translational tissue engineering remains challenging. 3D printing, an additive manufacturing technique, has revolutionized the field of tissue engineering by fabricating biomimetic tissue constructs with precisely controlled composition, spatial distribution, and architecture that can replicate both biological and functional native tissues. Therefore, 3D printing is gaining increasing attention as a viable option to advance personalized therapy for various diseases by regenerating the desired tissues. This review outlines the recently developed 3D printing techniques for clinical translation and specifically summarizes the applications of these approaches for the regeneration of cartilage, bone, and osteochondral tissues. The current challenges and future perspectives of 3D printing technology are also discussed.

Controlling Light in Scattering Materials for Volumetric Additive Manufacturing

3D printing has revolutionized the manufacturing of volumetric components and structures in many areas. Several fully volumetric light-based techniques have been recently developed thanks to the advent of photocurable resins, promising to reach unprecedented short print time (down to a few tens of seconds) while keeping a good resolution (around 100 μm). However, these new approaches only work with homogeneous and relatively transparent resins so that the light patterns used for photo-polymerization are not scrambled along their propagation. Herein, a method that takes into account light scattering in the resin prior to computing projection patterns is proposed. Using a tomographic volumetric printer, it is experimentally demonstrated that implementation of this correction is critical when printing objects whose size exceeds the scattering mean free path. To show the broad applicability of the technique, functional objects of high print fidelity are fabricated in hard organic scattering acrylates and soft cell-laden hydrogels (at 4 million cells mL-1 ). This opens up promising perspectives in printing inside turbid materials with particular interesting applications for bioprinting cell-laden constructs.

Additive manufacturing: Frameworks for chemical understanding and advancement in vat photopolymerization

Three-dimensional printing, or additive manufacturing (AM), is a broad term for a wide range of fabrication methods utilizing materials such as small-molecule, polymer, and metal feedstocks. Each method requires different chemical, physical, and engineering needs to be successful. This article will discuss some of the considerations for polymer-based AM methods. Ultimately, we focus on the chemistries of vat photopolymerization, in which light is used to cure a resin from liquid to solid, to provide an example of how chemical advancements have led to increased speed, resolution, and multimaterial printing capabilities not previously possible.

The 3D Bioprinted Scaffolds for Wound Healing

Skin tissue engineering and regeneration aim at repairing defective skin injuries and progress in wound healing. Until now, even though several developments are made in this field, it is still challenging to face the complexity of the tissue with current methods of fabrication. In this review, short, state-of-the-art on developments made in skin tissue engineering using 3D bioprinting as a new tool are described. The current bioprinting methods and a summary of bioink formulations, parameters, and properties are discussed. Finally, a representative number of examples and advances made in the field together with limitations and future needs are provided.