Roll-to-roll, high-resolution 3D printing of shape-specific particles

Jason M. Kronenfeld, Lukas Rother, Max A. Saccone, Maria T. Dulay and Joseph M. DeSimone ()
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Jason M. Kronenfeld: Stanford University
Lukas Rother: Stanford University
Max A. Saccone: Stanford University
Maria T. Dulay: Stanford University
Joseph M. DeSimone: Stanford University

Nature, 2024, vol. 627, issue 8003, 306-312

Abstract: Abstract Particle fabrication has attracted recent attention owing to its diverse applications in bioengineering1,2, drug and vaccine delivery3–5, microfluidics6,7, granular systems8,9, self-assembly5,10,11, microelectronics12,13 and abrasives14. Herein we introduce a scalable, high-resolution, 3D printing technique for the fabrication of shape-specific particles based on roll-to-roll continuous liquid interface production (r2rCLIP). We demonstrate r2rCLIP using single-digit, micron-resolution optics in combination with a continuous roll of film (in lieu of a static platform), enabling the rapidly permutable fabrication and harvesting of shape-specific particles from a variety of materials and with complex geometries, including geometries not possible to achieve with advanced mould-based techniques. We demonstrate r2rCLIP production of mouldable and non-mouldable shapes with voxel sizes as small as 2.0 × 2.0 µm2 in the print plane and 1.1 ± 0.3 µm unsupported thickness, at speeds of up to 1,000,000 particles per day. Such microscopic particles with permutable, intricate designs enable direct integration within biomedical, analytical and advanced materials applications.

Date: 2024
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DOI: 10.1038/s41586-024-07061-4

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