ABSTRACT
Volumetric additive manufacturing techniques are a promising pathway to ultra-rapid light-based 3D fabrication. Their widespread adoption, however, demands significant improvement in print fidelity. Currently, volumetric additive manufacturing prints suffer from systematic undercuring of fine features, making it impossible to print objects containing a wide range of feature sizes, precluding effective adoption in many applications. Here, we uncover the reason for this limitation: light dose spread in the resin due to chemical diffusion and optical blurring, which becomes significant for features ⪠0.5 mm. We develop a model that quantitatively predicts the variation of print time with feature size and demonstrate a deconvolution method to correct for this error. This enables prints previously beyond the capabilities of volumetric additive manufacturing, such as a complex gyroid structure with variable thickness and a fine-toothed gear. These results position volumetric additive manufacturing as a mature 3D printing method, all but eliminating the gap to industry-standard print fidelity.
ABSTRACT
Additive manufacturing (AM), in its little more than 40 years of existence, has already established itself as a technology with enormous potential for several fields, especially the ones that require complex, high resolution, small structures, such as tissue engineering. This field has been especially attracted to the most recent AM evolution, 4D printing, due to its ability to create structures responsive to external stimuli. Among the range of materials that are simultaneously suitable for 4D printing and biological uses, poly(N-isopropylacrylamide) (pNIPAM) stands out. pNIPAM presents exceptional characteristics such as a low critical solution temperature (LCST) close to the human physiological temperature and biocompatibility with several cell types. However, these characteristics are greatly affected by processing parameters. In this work, pNIPAM hydrogels were manufactured by AM using digital light processing; the printing temperature was varied between 5, 10 and 15 °C to analyze how it affects the hydrogels' final properties. The impact on hydrogels was analyzed by differential scanning calorimetry (DSC), swelling, deswelling and reswelling analyses, scanning electron microscopy (SEM) images, and compression tests. Based on our results increasing the production temperature of the hydrogels by 10 °C led to a decrease of more than 50% in the maximum swelling capacity, approximately 10% increase in water retention, and 6.5 °C variation in the LCST. The justification for such behaviour lies in the increase of the crosslinking rate and thickening of the external layer of hydrogels, which prevents the free movement of water from its interior.
