What if resin 3D printing could eliminate support structures entirely and make fabrication easier? That is the question explored by researchers at Xiamen University and the University of California, Berkeley. Together, they developed a new method for creating parts from a thermoset material without relying on any additional support structures. Their approach combines Direct Ink Writing with a laser curing system. They printed several test pieces to demonstrate the technique, and the parts were able to stand on their own. The next question is whether they will remain just as durable over time.
While many users appreciate the precision of resin 3D printing, it still comes with challenges, including long post-processing times that can slow down the entire workflow. Supports must be removed, parts must be washed, and then cured if necessary. Some manufacturers are working to minimize these steps, but this is still not common practice in the market and there is room for improvement. In addition, generating these supports is not always straightforward because the material properties make it difficult to maintain structural stability before curing. This is where the new research offers a promising alternative.
This technique employs a laser to directly solidify the material.
Dezhi Wu, a lead coauthor of the study, explains: “Thermoset materials (such as silicones) are widely used in engineering and infrastructure applications. However, their 3D printing processes suffer from prolonged curing time and complicate supporting structures to make freestanding structures as they will sag and collapse before solidification. The laser manufacturing tools in our lab are utilized to directly print thermoset ink materials to cure the ink instantly.“
The researchers rely on a laser that can be directed to solidify the material the moment it exits the syringe. This approach speeds up the printing process since the resin is cured immediately instead of requiring a dip into a resin vat or droplets projected onto a build plate. It also eliminates the need for support structures because the team is able to print directly “in midair.”
Another advantage highlighted by the researchers is that this process allows the mechanical and electrical properties of the materials to be programmed. Dezhi Wu explains, “The properties of printed 3D structures are programmable. For example, the local mechanical stiffness and electrical conductivity can be adjusted by the printing parameters so that different regions can be made softer or stiffer, and their conductivity can be high or low.“
Some examples of the 3D printed components.
The team 3D printed several structures to demonstrate the potential of their technique, including soft sensors, stretchable electronic components, and magnetic robots.
Dezhi Wu concluded, “We now plan to build a robust 3D-printing platform for the construction of soft, multi-functional devices,” added Wu. “We will also expand the printable ink toolbox and investigate the optimal printing parameters toward industrial applications, such as flexible electronics, organ chips and so on.” Until those developments arrive, you can find the study HERE.
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*All Photo Credits: Nature Electronics / Xiamen University