University of Pittsburgh engineers are developing a novel multi-wavelength additive manufacturing technique. Designed to be an affordable and agile approach superior to existing 3D manufacturing techniques, this method uses a unique optical system with multi-wavelength light sources to allow for the use of multiple materials and could improve manufacture of 3D multi-material objects with enhanced properties.
Description
Industries are seeking advancements in additive manufacturing to create functional, high-fidelity parts, using multiple materials for a broad spectrum of uses. Conventional techniques require extra handling of the materials being incorporated, leading to longer build times and limitations in the possible designs, bonding strength, geometric accuracy, and resolution. This novel approach could take advantage of a continuous manufacturing process to create advanced multi-material components with improved properties, providing benefit in fields such as electronics, bioprinting, and soft robotics.
Applications
- Constructing sensors and electronics
- Printing 4D actuators and soft robots
- Manufacturing complex materials with precision and speed, including for the defense sector
- Bioprinting physiological tissues and organs
Advantages
Existing techniques require materials to be printed layer by layer and involve a discontinuous manufacturing process. This method limits the use of multiple materials in the same layer, the design of components, slows printing speeds, reduces dimensional accuracy, and weakens structural integrity. In addition, the materials must be chemically similar due to the single-wavelength absorption and the otherwise lack of fusion between dissimilar materials.
This novel approach overcomes these challenges by using an optical system with multi-wavelength light sources. It will enable manufacturers to process materials continuously, both across and throughout layers to fabricate truly 3D multi-material components with improved geometric accuracy. The approach will improve the speed of manufacture by removing the need for material switchover, improve the mechanical strength of the product, and expand materials selection. Moreover, this multi-wavelength vat photopolymerization additive manufacturing process can also harness concurrent photoinhibition and photopolymerization to enhance the print resolution and speed.
Invention Readiness
A proof-of-concept system has been developed using two-wavelength mask projections, 460 nm and 365 nm, demonstrating successful printing of a pillar with multiple materials, a high degree of accuracy, and none of the problems of over curing. Work is now required to optimize the process to improve dimensional accuracy and multi-material selection.
IP Status
https://patents.google.com/patent/US20220143906A1
