Single-vat single-cure grayscale digital light processing 3D printing of materials with large property difference and high stretchability

Liang Yue, S. Macrae Montgomery, Xiaohao Sun, Luxia Yu, Yuyang Song, Tsuyoshi Nomura, Masato Tanaka and H. Jerry Qi ()
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Liang Yue: Georgia Institute of Technology
S. Macrae Montgomery: Georgia Institute of Technology
Xiaohao Sun: Georgia Institute of Technology
Luxia Yu: Georgia Institute of Technology
Yuyang Song: Toyota Motor North America
Tsuyoshi Nomura: Toyota Central R&D Laboratories, Inc., Bunkyo-ku
Masato Tanaka: Toyota Motor North America
H. Jerry Qi: Georgia Institute of Technology

Nature Communications, 2023, vol. 14, issue 1, 1-12

Abstract: Abstract Multimaterial additive manufacturing has important applications in various emerging fields. However, it is very challenging due to material and printing technology limitations. Here, we present a resin design strategy that can be used for single-vat single-cure grayscale digital light processing (g-DLP) 3D printing where light intensity can locally control the conversion of monomers to form from a highly stretchable soft organogel to a stiff thermoset within in a single layer of printing. The high modulus contrast and high stretchability can be realized simultaneously in a monolithic structure at a high printing speed (z-direction height 1 mm/min). We further demonstrate that the capability can enable previously unachievable or hard-to-achieve 3D printed structures for biomimetic designs, inflatable soft robots and actuators, and soft stretchable electronics. This resin design strategy thus provides a material solution in multimaterial additive manufacture for a variety of emerging applications.

Date: 2023
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DOI: 10.1038/s41467-023-36909-y

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