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A new manufacturing paradigm is showcased to exclude conventional mold‐dependent manufacturing of pressure sensors, which typically requires a series of complex and expensive patterning processes. This mold‐free manufacturing leverages high‐resolution 3D‐printed multiscale microstructures as the substrate and a gas‐phase conformal polymer coating technique to complete the mold‐free sensing platform. The array of dome and spike structures with a controlled spike density of a 3D‐printed substrate ensures a large contact surface with pressures applied and extended linearity in a wider pressure range. For uniform coating of sensing elements on the microstructured surface, oxidative chemical vapor deposition is employed to deposit a highly conformal and conductive sensing element, poly(3,4‐ethylenedioxythiophene) at low temperatures (<60 °C). The fabricated pressure sensor reacts sensitively to various ranges of pressures (up to 185 kPa⁻¹) depending on the density of the multiscale features and shows an ultrafast response time (≈36 µs). The mechanism investigations through the finite element analysis identify the effect of the multiscale structure on the figure‐of‐merit sensing performance. These unique findings are expected to be of significant relevance to technology that requires higher sensing capability, scalability, and facile adjustment of a sensor geometry in a cost‐effective manufacturing manner.

While vat photopolymerization has many advantages over soft lithography in fabricating microfluidic devices, including efficiency and shape complexity, it has difficulty achieving well-controlled micrometer-sized (smaller than 100 μm) channels in the layer building direction. The considerable light penetration depth of transparent resin leads to over-curing that inevitably cures the residual resin inside flow channels, causing clogs. In this paper, a 3D printing process — in-situ transfer vat photopolymerization is reported to solve this critical over-curing issue in fabricating microfluidic devices. We demonstrate microchannels with highZ-resolution (within 10 μm level) and high accuracy (within 2 μm level) using a general method with no requirements on liquid resins such as reduced transparency nor leads to a reduced fabrication speed. Compared with all other vat photopolymerization-based techniques specialized for microfluidic channel fabrication, our universal approach is compatible with commonly used 405 nm light sources and commercial photocurable resins. The process has been verified by multifunctional devices, including 3D serpentine microfluidic channels, microfluidic valves, and particle sorting devices. This work solves a critical barrier in 3D printing microfluidic channels using the high-speed vat photopolymerization process and broadens the material options. It also significantly advances vat photopolymerization’s use in applications requiring small gaps with high accuracy in theZ-direction.

3D objects with features spanning from microscale to macroscale have various applications. However, the fabrication of such objects presents challenges to additive manufacturing (AM) due to the tradeoffs among manufacturable feature resolution, maximum build area, and printing speed. This paper presents a projection‐based AM process called hopping light vat photopolymerization (HL‐VPP) to address this critical barrier. The key idea of HL‐VPP is to synchronize linear scanning projection with a galvo mirror's rotation. The projector moves continuously at a constant speed while periodically rotating a one‐axis galvo mirror to compensate for the projector's linear movement so synchronized hopping motion can be achieved. By this means, HL‐VPP can simultaneously achieve large‐area (over 200 mm), fast‐speed (scanning speed of 13.5 mm s^‐1), and high‐resolution (10 µm pixel size) fabrication. The distinguishing characteristic of HL‐VPP is that it allows for hundreds of times lower refresh rates without motion blur. Thus, HL‐VPP decouples the fabrication efficiency limit imposed by the refresh rate and will enable super‐fast curing in the future. This work will significantly advance VPP's use in applications that require macroscale part size with microscale features. The process has been verified by fabricating multiple multiscale objects, including microgrids and biomimetic structures.

Additive manufacturing has many advantages in creating highly complex customized structures. In this study, a low‐cost multiscale stereolithography technology that can print a macroscale object with microscale surface structures with high throughput is demonstrated. The developed multiscale stereolithography is realized by dynamic switching of laser spot size and adaptively sliced layer thickness. An optical filter based on subwavelength resonance grating is used to modify laser spot size for lasers with different wavelengths and achieves a maximum resolution of 37 µm. The multiscale stereolithography process has 4.4× throughput improvement compared with the traditional stereolithography process with a single laser spot. For proof‐of‐concept testing, artificial shark skins with microriblet features are designed and 3D printed. In pipe flow experiments, the 3D printed shark skin demonstrates almost 10% average fluid drag reduction. Artificial lotus leaf surfaces are also 3D printed to demonstrate superhydrophobic property. This new process has the potential to serve as a powerful tool that can bring bioinspired structures into real‐life applications.