Article
Engineering, Manufacturing
Ketki M. Lichade, Erina Baynojir Joyee, Yayue Pan
Summary: Video Projection-based Stereolithography (VP-SL) is a fast, low-cost, and high-resolution additive manufacturing process, but faces issues such as manufacturing defects and size constraints. This paper introduces a Gradient Light Video Projection-based Stereolithography (GLVP-SL) process that enables continuous fabrication of 3D solid objects with controlled exposure energy. The new process uses three mask images with unique grayscale distributions for each layer, and an optimization model is developed to determine the best grayscale distribution pattern for desired solid structure size and density. Experimental results show that GLVP-SL can produce void-free 3D solid objects with good surface quality.
JOURNAL OF MANUFACTURING PROCESSES
(2021)
Article
Engineering, Manufacturing
Iman Valizadeh, Ahmad Al Aboud, Edgar Doersam, Oliver Weeger
Summary: This paper explores the dependency of material properties on grayscale MSLA process parameters and formulates a grayscale-dependent hyperelastic material model. Through experimental validation, functionally graded structures with tailored mechanical properties are successfully achieved.
ADDITIVE MANUFACTURING
(2021)
Article
Polymer Science
Jordan T. Sutton, Kalavathy Rajan, David P. Harper, Stephen C. Chmely
Summary: Chemical modification techniques can reduce UV absorption by lignin, leading to improved stiffness and strength in resins when modified lignins are used. However, the thermal stability decreases. Studying these techniques is important for the development of lignin for UV-curing applications and commercial use.
Article
Chemistry, Multidisciplinary
Jeffrey C. Foster, Adam W. Cook, Nicolas T. Monk, Brad H. Jones, Leah N. Appelhans, Erica M. Redline, Samuel C. Leguizamon
Summary: The development of selective dual-wavelength olefin metathesis polymerization enables efficient initiation and fast reaction stoppage, allowing for 2D stereolithographic printing and 3D continuous additive manufacturing at high printing speeds.
Review
Biochemistry & Molecular Biology
Max J. Mannel, Elif Baysak, Julian Thiele
Summary: Droplet microfluidics has revolutionized high-throughput screening, directed evolution, single-cell sequencing, and material design. Traditional fabrication techniques have drawbacks, but high-resolution additive manufacturing like PμSL offers a promising solution. PμSL simplifies device fabrication, provides access to 3D geometries, is cost-effective, and enables multimaterial processing.
Review
Chemistry, Multidisciplinary
Alessandro Bove, Flaviana Calignano, Manuela Galati, Luca Iuliano
Summary: This review discusses the characteristics and properties of ceramic resins and the stereolithography process, as well as the complexity of post-processing phases.
APPLIED SCIENCES-BASEL
(2022)
Article
Materials Science, Ceramics
Wenxin Yang, Xiaoyan Meng, Peishen Ni, Zhe Zhao, Xin Deng, Shanghua Wu, Zhi Qu, Feng Jin
Summary: Weak bonding between diamond and matrix materials can be improved by coating diamond powder with Al2O3, which enhances thermal stability, reduces UV light absorbance, increases viscosity and curing depth sensitivity, and improves bonding condition between resin matrix and diamond powder, resulting in enhanced mechanical properties of diamond-resin composites in DLP 3D printing.
CERAMICS INTERNATIONAL
(2023)
Article
Polymer Science
Rossella Surace, Vito Basile, Vincenzo Bellantone, Francesco Modica, Irene Fassi
Summary: This study evaluated the feasibility of an AM/mu-IM process chain by designing and fabricating mold inserts using SLA technology, which were experimentally tested. The results confirm that producing mu-IM parts with an SLA fabricated mold insert is feasible, but requires high accuracy in material selection, mold design, fabrication, and assembly.
Article
Engineering, Manufacturing
Piljae Joo, Yimin Yao, Nicholas Teo, Sadhan C. Jana
Summary: A 3D-printing process is utilized to manufacture modular aerogel/acrylate bricks, which can be fully customized and scaled for thermal insulation applications. By combining 3D-printing tools with a sol-gel method for aerogel synthesis, the study overcomes the geometric limitations of producing large load-bearing aerogel products. The research focuses on the characteristics of two-component aerogel bricks and discusses the thermal properties and mechanical strength of the bricks in contact heating situations.
ADDITIVE MANUFACTURING
(2021)
Article
Engineering, Mechanical
Qin Qin, Jigang Huang, Jin Yao, Wenxiang Gao
Summary: This study proposes a method of multi-pass scanning and a compensation algorithm for SPSL systems to improve stitching quality, which has rarely been studied in previous work. The results demonstrate that multi-pass scanning is an effective approach to enhance stitching quality in SPSL systems, providing valuable advice for achieving satisfactory surface finish with SPSL technology.
RAPID PROTOTYPING JOURNAL
(2021)
Article
Biochemistry & Molecular Biology
Qirong Chen, Franziska Schmidt, Oliver Goerke, Anila Asif, Joachim Weinhold, Erfan Aghaei, Ihtesham Ur Rehman, Aleksander Gurlo, Asma Tufail Shah
Summary: In this study, a photocurable resin based on bioactive glass (BAG) was prepared for additive manufacturing of BAG scaffolds. The influence of BAG on the physical properties of the resin and resulting 3D structures was investigated. The rheology and photocuring behavior of the resin, as well as the tomography of the resulting structures, were studied by varying the concentration of monomers, reactive diluent, light absorber, photoinitiator, non-reactive diluent, and BAG fillers. The optimal resin composition was found to be 55-60% BAG, 10% PEG-200, 1% PI, and 0.015% dye. The resulting green bodies exhibited dense glass scaffolds with good interlayer connection and surface finishing, indicating promising mechanical behavior. This study provides valuable insights for the preparation and optimization of high density glass/ceramic slurries for printing applications.
Article
Chemistry, Multidisciplinary
Fiona Spirrett, Tatsuya Ito, Soshu Kirihara
Summary: The additive manufacturing of ceramics allows for fabrication of parts with complex geometries. Computational analysis methods, such as discrete element method and ray tracing, can be used to predict suitable material parameters and processing conditions for ceramic stereolithography, reducing the number of experimental iterations required for process optimization and achieving faster processing speed.
APPLIED SCIENCES-BASEL
(2022)
Article
Nanoscience & Nanotechnology
Ji Li, Yan Zhang, Peiren Wang, Guoqi Wang, Yifei Liu, Yaning Liu, Qianshuai Li
Summary: Direct manufacturing of customized end-use electronic products through additive manufacturing is a growing trend. A novel hybrid additive manufacturing solution that combines traditional AM processes with SLA 3D printing and laser-activated electroless plating has been proposed, enabling the creation of 3D fully functional electronic products with high-resolution circuitry and high-performance electrical materials.
ACS APPLIED MATERIALS & INTERFACES
(2021)
Article
Engineering, Manufacturing
Sergey Nechausov, Anna Ivanchenko, Oleg Morozov, Aslan Miriyev, Indrek Must, Oskars Platnieks, Maksims Jurinovs, Sergejs Gaidukovs, Alvo Aabloo, Mirko Kovac, Boris Bulgakov
Summary: This study investigates the effect of adding ionic liquids (ILs) on the vat photopolymerization (VP) process for the fabrication of ionogels (IGs). The results show that ILs can accelerate the polymerization reaction and increase the critical exposure energy for gelation. The study also demonstrates the changing penetration depth with different IL types and the impact of dual curing on the mechanical properties and ionic conductivity of the ionogels.
ADDITIVE MANUFACTURING
(2022)
Article
Chemistry, Multidisciplinary
Han Xu, Shuai Chen, Renzhi Hu, Muqun Hu, Yang Xu, Yeowon Yoon, Yong Chen
Summary: A new continuous projection-based vat photopolymerization process is reported that can directly shape polymer materials into optical lenses with microscale dimensional accuracy and nanoscale surface roughness without post-processing. The process utilizes frustum layer stacking to eliminate staircase aliasing, and a zooming-focused projection system to achieve continuous change of mask images and generate desired layer stacking. Experimental results demonstrate the effectiveness of the proposed process.
Article
Multidisciplinary Sciences
Yang Yang, Ziyu Wang, Qingqing He, Xiangjia Li, Gengxi Lu, Laiming Jiang, Yushun Zeng, Brandon Bethers, Jie Jin, Shuang Lin, Siqi Xiao, Yizhen Zhu, Xianke Wu, Wenwu Xu, Qiming Wang, Yong Chen
Summary: This study presents a rotation-blade casting-assisted 3D printing process for fabricating nacre-inspired structures with exceptional mechanical and flame-retardant properties. By modifying the surface of boron nitride nanoplatelets, the thermal conductivity and strength are enhanced, making it applicable for thermal control and protective materials manufacturing.
Article
Engineering, Manufacturing
Lifu Lin, Haidong Wu, Peishen Ni, Yong Chen, Zhaoquan Huang, Yehua Li, Kunji Lin, Pengfei Sheng, Shanghua Wu
Summary: This study focused on improving the heat dissipation performance of aluminum nitride (AlN) powder through surface modification. The effects of different silane coupling agents on the rheology, stability, and curing behavior of the AlN suspension were investigated. The study also examined the impact of various solid loadings on the curing behavior and properties of sintered AlN components. Additionally, a heat dissipation performance evaluation system was developed and showed that AlN ceramics with complex shapes have better heat-dissipation performance.
ADDITIVE MANUFACTURING
(2022)
Article
Multidisciplinary Sciences
Laiming Jiang, Gengxi Lu, Yushun Zeng, Yizhe Sun, Haochen Kang, James Burford, Chen Gong, Mark S. Humayun, Yong Chen, Qifa Zhou
Summary: The authors demonstrate a flexible piezo-array for ultrasound-induced retinal stimulation, which has the potential to restore functional vision and enhance quality of life in blind individuals.
NATURE COMMUNICATIONS
(2022)
Article
Engineering, Manufacturing
Yeowon Yoon, Yang Xu, Yong Chen
Summary: Inspired by natural porous morphology, a novel additive manufacturing process is proposed to fabricate porosity-embedded structures by integrating stereolithography and inkjet printing. Water droplets are dispensed onto a layer of liquid resin, which is then photocured to define the layer profile and capture the deposited water droplets. By varying inkjet printing parameters, the size and distribution of micropores in the 3D-printed part can be modulated.
JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME
(2023)
Article
Engineering, Manufacturing
Tengteng Tang, Bhushan Ahire, Xiangjia Li
Summary: This article introduces a novel manufacturing strategy that uses electrically assisted stereolithography to build bioinspired hierarchical structures with heterogeneous material systems. The formation mechanism of metallic structures on the polymer matrix was studied through physics-based multi-scale modeling and simulations, and the correlation between metallic structures morphology, printing solution properties, and printing process parameters in building bioinspired structures was identified.
JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME
(2023)
Article
Materials Science, Ceramics
Haidong Wu, Wei Liu, Lifu Lin, Yong Chen, Yuerui Xu, Shanghua Wu, Zhenzhong Sun, Di An, Sai Wei, Zhipeng Xie
Summary: Two types of coupling agents, aluminic acid ester and silane coupling agent, were used to modify Al2O3 ceramic powder based on transesterification reactions, solving the poor compatibility problem between ceramic powder and photosensitive resin in Vat photopolymerization. After pressureless sintering, hot isostatic pressing sintering was applied to further enhance the mechanical performance of the Al2O3 ceramic. Additionally, Al2O3 ceramic cutting tools with chip breaker grooves were successfully prepared and demonstrated superior cutting performance compared to commercial ceramic cutting tools.
JOURNAL OF THE EUROPEAN CERAMIC SOCIETY
(2023)
Article
Chemistry, Multidisciplinary
Tengteng Tang, Saleh Alfarhan, Kailong Jin, Xiangjia Li
Summary: In this study, a new 4D printing technology called liquid crystal templating-assisted vat photopolymerization (LCT-VPP) is introduced. This technology can fabricate bioinspired porous structures with hygro-responsive capabilities by utilizing photopolymerization induced phase separation (PIPS) and liquid crystals (LCs) electro-alignment. The results of this study have implications for designing bioinspired smart materials with special spatial distribution of porous structures.
ADVANCED FUNCTIONAL MATERIALS
(2023)
Article
Chemistry, Multidisciplinary
Yang Xu, Huachao Mao, Cenyi Liu, Zhengyu Du, Weijia Yan, Zhuoyuan Yang, Jouni Partanen, Yong Chen
Summary: This paper presents a projection-based AM process called hopping light vat photopolymerization (HL-VPP) to address the challenges of fabricating 3D objects with features spanning from microscale to macroscale. HL-VPP achieves large-area, fast-speed, and high-resolution fabrication by synchronizing linear scanning projection with a galvo mirror's rotation. The distinguishing characteristic of HL-VPP is its ability to achieve super-fast curing without motion blur, significantly advancing VPP's use in applications that require macroscale part size with microscale features.
Article
Multidisciplinary Sciences
Yuxuan Sun, Liu Wang, Yangyang Ni, Huajian Zhang, Xiang Cui, Jiahao Li, Yinbo Zhu, Ji Liu, Shiwu Zhang, Yong Chen, Mujun Li
Summary: The authors present an in situ dual heating strategy for the rapid 3D printing of thermosets with complex structures and diverse rheological properties. This strategy combines the direct ink writing (DIW) technique and a heating-accelerated in situ gelation mechanism, allowing for the printing of various thermosets with viscosities spanning five orders of magnitude, printed height over 100 mm, and high resolution of 50 μm.
NATURE COMMUNICATIONS
(2023)
Article
Engineering, Manufacturing
Yujie Shan, Yiyang Shui, Junyu Hua, Huachao Mao
Summary: This study proposes a heat-guided algorithm to generate nonplanar layers in additive manufacturing, addressing the limitations of conventional planar-layer-based processes. By using virtual isothermal surfaces, the 3D model is sliced into curved layers. Customized 3D printers were used to evaluate the proposed method, resulting in significant improvements in surface roughness, tensile strength, and printing time reduction.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
Article
Materials Science, Multidisciplinary
Tengteng Tang, Gana Sai Kiran Avinash Raj Dwarampudi, Xiangjia Li
Summary: An electrically assisted vat photopolymerization (e-VPP) method was proposed to control the surface roughness of Salvinia-inspired structures by introducing multiwalled carbon nanotubes (MWCNTs), which improves the superhydrophobic properties and overall performance of the bioinspired structures. The results show that MWCNTs can increase the superhydrophobicity of printed structures at a relatively high concentration and enhance mechanical strength, contact angle, and liquid surface attachment forces. This research enables the achievement of better interfacial performance with controllable micro-/nano-dual-scale surface roughness properties for various applications.
Article
Chemistry, Multidisciplinary
Han Xu, Shuai Chen, Renzhi Hu, Muqun Hu, Yang Xu, Yeowon Yoon, Yong Chen
Summary: A new continuous projection-based vat photopolymerization process is reported that can directly shape polymer materials into optical lenses with microscale dimensional accuracy and nanoscale surface roughness without post-processing. The process utilizes frustum layer stacking to eliminate staircase aliasing, and a zooming-focused projection system to achieve continuous change of mask images and generate desired layer stacking. Experimental results demonstrate the effectiveness of the proposed process.
Article
Biochemistry & Molecular Biology
Banashree Gogoi, Carson Gockley, Sushmitha Venu, Yizhen Zhu, Pranith Alluri, Ayinawu Abdul Malik, Mitesh Suhas Despande, Raveena Phadnis, Evangeline Amonoo, Xiangjia Li, Terry L. Alford
Summary: The importance of conductive polymers has increased due to their wide range of applications. The study developed a novel printing process called EF-DID to overcome the limitations of spin coating and achieve high conductivity films. The effects of nanodroplets formation and the use of dimethyl sulfoxide (DMSO) as an additive solvent were investigated.
Article
Biochemistry & Molecular Biology
Yizhen Zhu, Rohan Ravishekar, Tengteng Tang, Banashree Gogoi, Carson Gockley, Sushmitha Venu, Terry L. Alford, Xiangjia Li
Summary: Poly(3,4-ethylenedioxythiophene):poly(styrenesulfonate) (PEDOT:PSS) has emerged as a promising conductive polymer for hole-transport layers in perovskite solar cells. Conventional fabrication methods have resulted in PEDOT:PSS nanofilms with limited performance. This study introduces a novel 3D printing approach that combines programmable acoustic field modulation with electrohydrodynamic spraying, allowing for precise control of PEDOT:PSS nanofilm morphology. The experimental findings show that horizontal ultrasonic vibrations result in a uniform dispersion of PEDOT:PSS nanoparticles, and when applied at low amplitude during printing, the nanofilms exhibit exceptional wettability and impressive electrical conductivity. This approach holds great promise for various nanotechnological applications.
Article
Chemistry, Multidisciplinary
Jie Jin, Fangzhou Zhang, Yulong Yang, Chengqian Zhang, Haidong Wu, Yang Xu, Yong Chen
Summary: This article introduces a novel hybrid 3D printing technique that combines the strengths of vat photopolymerization and direct-ink-writing processes to achieve multimaterial and high-resolution printing of functional structures and devices. The method involves dispensing liquid-like materials into a photocurable matrix material and using a controlled laser beam to selectively photocure the dispensed material trace or the matrix material. The versatility of the method is demonstrated by fabricating intricate 3D prototypes using various materials available for vat photopolymerization and direct-ink-writing technologies.
