Nature never ceases to surprise us. It is also a great source of inspiration for the additive manufacturing market, as demonstrated by a recent study published by the University of Illinois Urbana-Champaign. It highlights a new 3D printing method, called 3DPX, which is capable of designing ultra-fine fibers, with a diameter of just 1.5 microns.
This process relies on the use of a viscoplastic fluid rheology support gel to print highly complex fibrous structures. The 3D printer’s nozzle is able to move in this gel, freeing itself from the gravitational constraints posed by this type of extremely fine fiber. The team behind this new approach to 3D printing hopes that it will enable the development of applications in the robotics, medical and materials sectors.
Who hasn’t been fascinated by the resistance of a spider’s web, the protective function of an eggshell or the strength of the silk that enables certain insects to capture their prey? When you think about it, these structures are impressive and an inexhaustible source of learning.
Indeed, this is the reason that additive manufacturing and biomimicry are regularly combined to offer new applications. And this time, the aim was to find a solution in order to reproduce these fine fibers to scale. However, reproducing the properties of these networks in 3D form is extremely complex.
Different shapes 3D printed using the 3DPX method
The researchers have developed a method they call “embedded 3D printing by solvent exchange” (3DPX). One of the problems with printing such soft materials and thin structures is that they do not have sufficient flexural rigidity to support their own weight. The researchers therefore opted to print in a vat of gel, which acts as a printing medium.
They explain, “To obtain filaments with a diameter of less than 1.5 µm, we modified the yield point rheology of the supporting gel and the compositions of the polymer, solvent and non-solvent, all of which play an essential role in the process.”
Several tests were carried out to prove the full potential of this technique. These showed that it was possible to produce 1.5-micron fibers using a 5-micron nozzle. Various materials were used, including elastomers, PVC and polystyrene. The researchers believe that this method could have an impact in the medical sector, for example, in drug delivery or the design of ultra-precise microfluidic devices; in the electronics sector; or in sensor design.
There are still a few hurdles to overcome before this method can be more widely used, such as achieving greater stability, or perfecting material formulation. But the initial results are encouraging, and show how additive manufacturing can achieve very small levels of finesse. You can find out more in the study HERE.
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*Cover Photo Credits: Tanver Hossain