Rather than building up plastic filaments layer by layer, a new approach to 3D printing lifts complex shapes from a vat of liquid at up to 100 times faster than conventional 3D printing processes, University of Michigan researchers have shown.
3D printing could change the game for relatively small manufacturing jobs, producing fewer than 10,000 identical items, because it would mean that the objects could be made without the need for a mold costing upwards of $10,000. But the most familiar form of 3D printing, which is sort of like building 3D objects with a series of 1D lines, hasn’t been able to fill that gap on typical production timescales of a week or two.
“Using conventional approaches, that’s not really attainable unless you have hundreds of machines,” said Timothy Scott, U-M associate professor of chemical engineering who co-led the development of the new 3D printing approach with Mark Burns, the T.C. Chang Professor of Engineering at U-M.
Their method solidifies the liquid resin using two lights to control where the resin hardens—and where it stays fluid. This enables the team to solidify the resin in more sophisticated patterns. They can make a 3D bas-relief in a single shot rather than in a series of 1D lines or 2D cross-sections. Their printing demonstrations include a lattice, a toy boat and a block M.
“It’s one of the first true 3D printers ever made,” said Burns, professor of chemical engineering and biomedical engineering.
But the true 3D approach is no mere stunt—it was necessary to overcome the limitations of earlier vat-printing efforts. Namely, the resin tends to solidify on the window that the light shines through, stopping the print job just as it gets started.
By creating a relatively large region where no solidification occurs, thicker resins—potentially with strengthening powder additives—can be used to produce more durable objects. The method also bests the structural integrity of filament 3D printing, as those objects have weak points at the interfaces between layers.
“You can get much tougher, much more wear-resistant materials,” Scott said.
An earlier solution to the solidification-on-window problem was a window that lets oxygen through. The oxygen penetrates into the resin and halts the solidification near the window, leaving a film of fluid that will allow the newly printed surface to be pulled away.
But because this gap is only about as thick as a piece of transparent tape, the resin must be very runny to flow fast enough into the tiny gap between the newly solidified object and the window as the part is pulled up. This has limited vat printing to small, customized products that will be treated relatively gently, such as dental devices and shoe insoles.
By replacing the oxygen with a second light to halt solidification, the Michigan team can produce a much larger gap between the object and the window—millimeters thick—allowing resin to flow in thousands of times faster.
The key to success is the chemistry of the resin. In conventional systems, there is only one reaction. A photoactivator hardens the resin wherever light shines. In the Michigan system, there is also a photoinhibitor, which responds to a different wavelength of light.
Rather than merely controlling solidification in a 2D plane, as current vat-printing techniques do, the Michigan team can pattern the two kinds of light to harden the resin at essentially any 3D place near the illumination window.
U-M has filed three patent applications to protect the multiple inventive aspects of the approach, and Scott is preparing to launch a startup company.
A paper describing this research will be published in Science Advances, titled, “Rapid, continuous additive manufacturing by volumetric polymerization inhibition patterning.”
Learn more: 3D printing 100 times faster with light
The Latest on: 3D printing
via Google News
The Latest on: 3D printing
- OU's Formula SAE Chapter Makes 3D-Printed Face Shieldson May 11, 2020 at 7:54 am
One of your neighbors posted in Community Corner. Click through to read what they have to say. (The views expressed in this post are the author’s own.) ...
- Global Market for 3D Printing Market 2020-2027: Increasing Adoption of 3D Printers in Healthcare, Automotive and Consumer Electronics Verticals Set to Boost Market Growth ...on May 11, 2020 at 1:03 am
The "3D Printing Market Size, Share & Trends Analysis Report by Material, by Component (Hardware, Services), by Printer Type (Desktop, Industrial), by Technology, by Software, by Application, by ...
- COVID-19 Impact and Recovery Analysis- 3D Printing Metal Materials Market 2020-2024 | Use Of 3D Technology In The Aerospace Sector to Boost Growth | Technavioon May 10, 2020 at 11:00 pm
Technavio has announced its latest market research report titled Global 3D Printing Metal Materials Market 2020-2024 (Graphic: Business Wire) LONDON-- ( BUSINESS WIRE )--Technavio has been monitoring ...
- UAE based 3D printing firm to make PPE for COVID-19on May 10, 2020 at 6:06 am
Proto21, a Dubai-based 3D printing company, has collaborated with the Dubai Police to manufacture more than 1,000 reusable 3D printed face shields for its frontline officers.The personal protective ...
- 3D Printing Has Entered The Nuclear Realmon May 9, 2020 at 8:04 am
D-printing has come to nuclear and it’s saving a lot of time and money, like 90%. Right now, it’s best for small spare parts, in developing micro-reactors, and in using new high-tech materials like ...
- The best 3D printer for beginners and budget creators for 2020on May 8, 2020 at 2:30 pm
Fire up the 3D printer and even print your own face masks and other pandemic accessories. COVID-19 has brought into focus a sharper need for 3D printing know-how. Individuals and bigger companies like ...
- This 3D-printed foam expands up to 40 times its original sizeon May 8, 2020 at 1:11 pm
Until now, the size of 3D-printed objects has been limited by the size of 3D printers. In most cases, in order to produce large items used in, say, aerospace, manufactures have had to fasten, weld or ...
- 3D Printing And The Shifting Legal Landscape For COVID-19on May 8, 2020 at 12:12 pm
As the 3D printing community steps in to address the shortage of critical medical supplies, attorneys at Arnold & Porter highlight key issues regarding the scope of new immunities, the evolving U.S.
- Global 3D Printing Materials Market Analysis & Trends, 2020 - ResearchAndMarkets.comon May 8, 2020 at 5:26 am
Industry Forecast to 2028" report has been added to ResearchAndMarkets.com's offering. The Global 3D Printing Materials Market is poised to grow strong during the forecast period 2018 to 2028. Some of ...
- Global 3D Printing Material Market 2020-2024: Profiles of Leading Players Including Arcam AB, Voxeljet AG and The ExOne Companyon May 8, 2020 at 4:01 am
The "Technology Landscape, Trends and Opportunities in 3D Printing Material Market" report has been added to ResearchAndMarkets.com's.
via Bing News