skip to main content
US FlagAn official website of the United States government
dot gov icon
Official websites use .gov
A .gov website belongs to an official government organization in the United States.
https lock icon
Secure .gov websites use HTTPS
A lock ( lock ) or https:// means you've safely connected to the .gov website. Share sensitive information only on official, secure websites.

Explore Research Products in the PAR
It may take a few hours for recently added research products to appear in PAR search results.


Title: Acoustophoretic Liquefaction for 3D Printing Ultrahigh‐Viscosity Nanoparticle Suspensions
Abstract An acoustic liquefaction approach to enhance the flow of yield stress fluids during Digital Light Processing (DLP)‐based 3D printing is reported. This enhanced flow enables processing of ultrahigh‐viscosity resins (μapp > 3700 Pa s at shear rates  = 0.01 s–1) based on silica particles in a silicone photopolymer. Numerical simulations of the acousto–mechanical coupling in the DLP resin feed system at different agitation frequencies predict local resin flow velocities exceeding 100 mm s–1at acoustic transduction frequencies of 110 s–1. Under these conditions, highly loaded particle suspensions (weight fractions, ϕ = 0.23) can be printed successfully in complex geometries. Such mechanically reinforced composites possess a tensile toughness 2000% greater than the neat photopolymer. Beyond an increase in processible viscosities, acoustophoretic liquefaction DLP (AL‐DLP) creates a transient reduction in apparent viscosity that promotes resin recirculation and decreases viscous adhesion. As a result, acoustophoretic liquefaction Digital Light Processing (AL‐DLP) improves the printed feature resolution by more than 25%, increases printable object sizes by over 50 times, and can build parts >3 × faster when compared to conventional methodologies.  more » « less
Award ID(s):
1719875
PAR ID:
10362885
Author(s) / Creator(s):
 ;  ;  ;  ;  ;  ;  ;  ;  ;  ;  
Publisher / Repository:
Wiley Blackwell (John Wiley & Sons)
Date Published:
Journal Name:
Advanced Materials
Volume:
34
Issue:
7
ISSN:
0935-9648
Format(s):
Medium: X
Sponsoring Org:
National Science Foundation
More Like this
  1. ; ; ; ; ; ; ; ; ; ; et al (, Advanced Materials)
    Abstract The development of a low‐cost photopolymer resin to fabricate optical glass of high refractive index for plastic optics is reported. This new free radically polymerizable photopolymer resin, termed, disulfide methacrylate resin (DSMR) is synthesized by the direct addition of allyl methacrylate to a commodity sulfur petrochemical, sulfur monochloride (S2Cl2). The rapid rates of free radical photopolymerization confer significant advantages in preparing high‐quality, bulk optical glass. The low‐cost, optical glass produced from this photopolymer possesses a desirable combination of high refractive index (n ≈ 1.57–1.59), low birefringence (Δn < 10−4), high glass transition values (Tg ≈ 100 °C), along with optical transparency rivaling, or exceeding that of poly(methyl methacrylate) (PMMA) as indicated by very low optical absorption coefficients (α < 0.05 cm−1at 1310 nm) measured for thick glass DSMR photopolymer samples (diameter (D) = 25 mm; thickness = 1–30 mm). The versatile manufacturability of DSMR photopolymers for both molding and diamond turn machining methods is demonstrated to prepare precision optics and nano‐micropatterned arrays. Finally, large‐scale 3D printing vat photopolymerization of DSMR using high‐area rapid printing digital light processing additive manufacturing is demonstrated. 
    more » « less
  2. ; ; ; ; ; (, IEEE International Conference on Soft Robotics (RoboSoft))
    Soft, stretchable sensors, such as artificial skins or tactile sensors, are attractive for numerous soft robotic applications due to the low material compliance. Conductive polymers are a necessary component of many soft sensors, and this work presents the electromechanical characterization of 3D-printable conductive polymer composites. Dog-bone shaped samples were 3D printed using a digital light processing (DLP)-based 3D printer for characterization. The 3D printable resin consists of monomer, crosslinker, conductive nano-filler, and a photo-initiator. The characterization was performed in two tracks. First, the effect of two different crosslinkers was investigated with different compositions and second, the effect of concentration of conductive nano-fillers was explored. Crosslinkers were chosen by referring to previous studies, and carbon nanotubes (CNTs) were utilized as conductive nano-fillers. The samples were 3D printed and characterized using an electromechanical test setup. To demonstrate utility for 3D printed soft robotics, a capacitance-based joystick sensor composed of both conductive and non-conductive resins was 3D printed. 
    more » « less
  3. ; ; ; ; ; ; ; (, Advanced Materials)
    Abstract Fabricating polymeric composites with desirable characteristics for electronic applications is a complex and costly process. Digital light processing (DLP) 3D printing emerges as a promising technique for manufacturing intricate structures. In this study, polymeric samples are fabricated with a conductivity difference exceeding three orders of magnitude in various portions of a part by employing grayscale DLP (g‐DLP) single‐vat single‐cure 3D printing deliberate resin design. This is realized through the manipulation of light intensity during the curing process. Specifically, the rational resin design with added lithium ions results in the polymer cured under the maximum UV‐light intensity exhibiting higher electrical resistance. Conversely, sections that are only partially cured retains uncured monomers, serving as a medium that facilitates ion mobility, consequently leading to higher conductivity. The versatility of g‐DLP allows precise control of light intensity in different regions during the printing process. This characteristic opens up possibilities for applications, notably the low‐cost, facile, and rapid production of complex electrical circuits and sensors. The utilization of this technique makes it feasible to fabricate materials with tailored conductivity and functionality, providing an innovative pathway to advance the accelerated and facile creation of sophisticated electronic devices. 
    more » « less
  4. ; ; ; ; ; ; ; (, American Society of Mechanical Engineers)
    Abstract The development of smart materials capable of dynamic shape morphing and rapid responsiveness has garnered significant interest for applications in soft robotics, tissue engineering, programmable materials, and adaptive structures. Hydrogels, owing to their intrinsic biocompatibility and flexibility, are promising candidates for such systems. Embedding micro-scale materials within hydrogel networks can further enhance their mechanical and functional properties. In this study, we present a hybrid fabrication platform that integrates surface acoustic wave (SAW)-based acoustofluidics with digital light processing (DLP) photopolymerization to fabricate smart hydrogel composites with programmable shape-memorable behavior. Using the SAW-induced acoustic potential field, silicon carbide (SiC) micro-whiskers are aligned within a custom UV-curable hydrogel ink and subsequently fixed via high-resolution DLP photopolymerization. This dual-control approach enables independent manipulation of micro-whisker orientation and structural geometry. Numerical simulations and Laser Doppler vibrometry-based validation were employed to characterize the acoustic field. To evaluate shape-memory behavior, the fabricated hydrogels were subjected to dehydration and rehydration cycles. The resulting shape transformations, driven by internal stress gradients within the aligned microparticle framework, enabled humidity-responsive actuation. This work establishes a novel strategy for constructing 4D-printed smart hydrogels, offering a versatile platform for the development of next-generation programmable materials and adaptive structures. 
    more » « less
  5. ; ; ; ; ; ; ; ; ; ; et al (, Biofabrication)
    Abstract Thrombosis in the circulation system can lead to major myocardial infarction and cardiovascular deaths. Understanding thrombosis formation is necessary for developing safe and effective treatments. In this work, using digital light processing (DLP)-based 3D printing, we fabricated sophisticated in vitro models of blood vessels with internal microchannels that can be used for thrombosis studies. In this regard, photoacoustic microscopy (PAM) offers a unique advantage for label-free visualization of the 3D-printed vessel models, with large penetration depth and functional sensitivity. We compared the imaging performances of two PAM implementations: optical-resolution PAM and acoustic-resolution PAM, and investigated 3D-printed vessel structures with different patterns of microchannels. Our results show that PAM can provide clear microchannel structures at depths up to 3.6 mm. We further quantified the blood oxygenation in the 3D-printed vascular models, showing that thrombi had lower oxygenation than the normal blood. We expect that PAM can find broad applications in 3D printing and bioprinting for in vitro studies of various vascular and other diseases. 
    more » « less
  • Citation Formats
  • MLA
  • APA
  • Chicago
  • BibTeX
  • Save / Share this Record
  • Send to Email