3D printing has transformed manufacturing in a variety of industries, enabling everything from the production of prototypes to the creation of complex biomedical structures. Among current technologies, digital light processing (DLP) has become especially popular for its speed and accuracy. However, this approach faced limitations in terms of material uniformity and heat dissipation – until now! Researchers at the University of Melbourne have come up with an innovative solution: Dynamic Interface Printing (DIP), a technique that promises to revolutionize bioprinting.
The new DIP process was presented in the journal Nature and introduces a disruptive approach that shifts the printing point to the meniscus, i.e. the surface curve of the precursor liquid. This strategic shift enables greater control over material flow and optimizes heat dissipation, two crucial elements for high-precision, high-speed 3D printing.
CAD model of the DIP printing system and its mechanical components.
What Makes This New Process Special?
The Dynamic Interface Printing process uses a pressurized tubular printhead that sits above a tank of liquid. This head is designed to project light patterns onto the meniscus, i.e. the surface of the liquid, through controlled acoustic vibrations. This step allows the printing surface to be shaped and stabilized. This process allows the material to build up uniformly and continuously, avoiding heating problems and printing errors. The printing speed with DIP can reach 0.7 millimeters per second, a considerable advance over what we knew until now.
The potential of the new process is immense, especially in bioprinting, where precision and biocompatibility are important. Thanks to its ability to print at high resolution and directly on laboratory plates, this method could accelerate the creation of complex cellular structures. During testing, the scientists demonstrated its effectiveness in increasing cell survival rate and reducing printing time, while eliminating the need for physical manipulation and ensuring the sterility of the process.
Above, parts printed with the new DIP system and, below, their CAD models.
Applications range from the production of biological models to the creation of living tissue. Callum Vidler, one of the lead authors, shares that “Biologists recognize the immense potential of bioprinting, but until now, it has been limited to applications with a very low output.” The new DIP process can overcome these limits, offering significant improvements in speed, accuracy and consistency. He continues, “This creates a crucial bridge between lab research and clinical applications.”
The Australian team’s collaboration with more than 60 researchers, including specialists from Harvard Medical School and Sloan Kettering Cancer Center, highlights the global interest in this technology. As Vidler notes, “the feedback has been overwhelmingly positive.”
The Future of Light Manufacturing
Dynamic Interface Printing represents a significant advance for bioprinting and 3D manufacturing, with a technique that redefines the use of light to achieve high precision. The combination of speed, biocompatibility and precision offered by the new process could open a new era for 3D printing.
As its creators point out, this technology “fills a gap” in bioprinting and marks the beginning of a future where current technical limitations are overcome. You can learn more HERE.
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*All Photo Credits: Nature