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Embedded ink writing (EIW) and direct ink writing (DIW) constitute the primary strategies for three-dimensional (3D) printing within the realm of material extrusion. These methods enable the rapid fabrication of complex 3D structures, utilizing either yield-stress support baths or self-supporting inks. Both these strategies have been extensively studied across a range of fields, including biomedical, soft robotics, and smart sensors, due to their outstanding print fidelity and compatibility with diverse ink materials. Particle additives capable of forming volume-filling 3D networks are frequently incorporated into polymer solvents. This integration is crucial for engineering the requisite microstructures essential for the formulation of successful support bath and ink materials. The interplay between the particle additives and polymer solvents is critical for achieving rheological tunability in various 3D printing strategies, yet this area has not been systematically reviewed. Therefore, in this critical review, we examined various mechanisms of particle–polymer interactions, the resulting microstructures, and their subsequent impact on mechanical and rheological properties. Overall, this work aims to serve as a foundational guideline for the design of next-generation materials in the field of extrusion additive manufacturing, specifically for EIW and DIW.
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Three-dimensional printing with sacrificial materials for soft matter manufacturing
Three-dimensional (3D) printing has expanded beyond the mere patterned deposition of melted solids, moving into areas requiring spatially structured soft matter—typically materials composed of polymers, colloids, surfactants, or living cells. The tunable and dynamically variable rheological properties of soft matter enable the high-resolution manufacture of soft structures. These rheological properties are leveraged in 3D printing techniques that employ sacrificial inks and sacrificial support materials, which go through reversible solid–fluid transitions under modest forces or other small perturbations. Thus, a sacrificial material can be used to shape a second material into a complex 3D structure, and then discarded. Here, we review the sacrificial materials and related methods used to print soft structures. We analyze data from the literature to establish manufacturing principles of soft matter printing, and we explore printing performance within the context of instabilities controlled by the rheology of soft matter materials.
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- Award ID(s):
- 1352043
- PAR ID:
- 10085331
- Date Published:
- Journal Name:
- MRS Bulletin
- Volume:
- 42
- Issue:
- 08
- ISSN:
- 0883-7694
- Page Range / eLocation ID:
- 571 to 577
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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- Free Publicly Accessible Full Text
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Accepted Manuscript
- Journal Article:
- https://doi.org/10.1557/mrs.2017.167
