Multi-Material Digital Light Processing Printer With Material Tower and Spray Cleaning

2018 ◽  
Author(s):  
Christopher-Denny Matte ◽  
Michael Pearson ◽  
Felix Trottier-Cournoyer ◽  
Andrew Dafoe ◽  
Tsz-Ho Kwok
Keyword(s):  
3D Printing ◽  
Material Handling ◽  
Three Dimensional ◽  
Cross Contamination ◽  
Digital Light Processing ◽  
Storage And Retrieval ◽  
Cleaning System ◽  
Multiple Materials ◽  
Compact Design ◽  
Planar Component

Digital light processing (DLP) three-dimensional (3D) printing is a type of stereolithography (SLA) process that uses a digital projector to selectively cure resin according to a mask image. Each exposure solidifies a planar component of the printed part, allowing full layers to be cured at once. The DLP approach produces better quality parts at a faster rate compared to other 3D printing methods. One of the challenges with DLP printing is the difficulty of incorporating multiple materials within the same part. As the part is cured within a liquid basin, resin switching introduces issues of cross-contamination, layer height variability, and significantly increased print times. In this paper, a novel technique for printing with multiple materials using the DLP method is introduced. The material handling challenges are addressed with the design of a material swapping mechanism, a material tower, and an active part cleaning system. The material tower is a compact design to facilitate the storage and retrieval of different materials during the printing process. A spray mechanism is used for cleaning excess resin from the part between material changes. Challenges encountered within the 3D printing research community are addressed, with a focus on improving the shortcomings of modern multi-material DLP printers.

Automated storage and active cleaning for multi-material digital-light-processing printer

2019 ◽  
Vol 25 (5) ◽  
pp. 864-874 ◽  
Author(s):  
Christopher-Denny Matte ◽  
Michael Pearson ◽  
Felix Trottier-Cournoyer ◽  
Andrew Dafoe ◽  
Tsz Ho Kwok
Keyword(s):  
Material Handling ◽  
Storage System ◽  
Digital Light Processing ◽  
Content Type ◽  
Storage And Retrieval ◽  
Retrieval Systems ◽  
Cleaning Solution ◽  
Multiple Materials ◽  
Automated Storage ◽  
Compact Design

PurposeThe purpose of this paper is to introduce a novel technique for printing with multiple materials using the DLP method. Digital-light-processing (DLP) printing uses a digital projector to selectively cure a full layer of resin using a mask image. One of the challenges with DLP printing is the difficulty of incorporating multiple materials within the same part. As the part is cured within a liquid basin, resin switching introduces issues of cross-contamination and significantly increased print time.Design/methodology/approachThe material handling challenges are investigated and addressed by taking inspiration from automated storage and retrieval systems and using an active cleaning solution. The material tower is a compact design to facilitate the storage and retrieval of different materials during the printing process. A spray mechanism is used for actively cleaning excess resin from the part between material changes.FindingsChallenges encountered within the multi-material DLP technology are addressed and the experimental prototype validates the proposed solution. The system has a cleaning effectiveness of over 90 per cent in 15 s with the build area of 72 inches, in contrast to the previous work of 50 per cent cleaning effectiveness in 2 min with only 6 inches build area. The method can also hold more materials than the previous work.Originality/valueThe techniques from automated storage and retrieval system is applied to develop a storage system so that the time complexity of swapping is reduced from linear to constant. The whole system is sustainable and scalable by using a spraying mechanism. The design of the printer is modular and highly customizable, and the material waste for build materials and cleaning solution is minimized.

Multi-material stereolithography using curing-on-demand printheads

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Huachao Mao ◽  
Wenxuan Jia ◽  
Yuen-Shan Leung ◽  
Jie Jin ◽  
Yong Chen
Keyword(s):  
Three Dimensional ◽  
Layer By Layer ◽  
Digital Light Processing ◽  
Content Type ◽  
On Demand ◽  
Digitally Controlled ◽  
Multiple Materials ◽  
Dimensional Object ◽  
Compact Design ◽  
Printing Method

Purpose This paper aims to present a multi-material additive manufacturing (AM) process with a newly developed curing-on-demand method to fabricate a three-dimensional (3D) object with multiple material compositions. Design/methodology/approach Unlike the deposition-on-demand printing method, the proposed curing-on-demand printheads use a digital light processing (DLP) projector to selectively cure a thin layer of liquid photocurable resin and then clean the residual uncured material effectively using a vacuuming and post-curing device. Each printhead can individually fabricate one type of material using digitally controlled mask image patterns. The proposed AM process can accurately deposit multiple materials in each layer by combining multiple curing-on-demand printheads together. Consequently, a three-dimensional object can be fabricated layer-by-layer using the developed curing-on-demand printing method. Findings Effective cleaning of uncured resin is realized with reduced coated resin whose height is in the sub-millimeter level and improved vacuum cleaning performance with the uncleaned resin less than 10 µm thick. Also, fast material swapping is achieved using the compact design of multiple printheads. Originality/value The proposed multi-material stereolithography (SL) process enables 3D printing components using more viscous materials and can achieve desired manufacturing characteristics, including high feature resolution, fast fabrication speed and low machine cost.

scholarly journals 3D Printing of Thermo-Sensitive Drugs

Pharmaceutics ◽  
2021 ◽  
Vol 13 (9) ◽  
pp. 1524
Author(s):  
Sadikalmahdi Abdella ◽  
Souha H. Youssef ◽  
Franklin Afinjuomo ◽  
Yunmei Song ◽  
Paris Fouladian ◽  
...  
Keyword(s):  
3D Printing ◽  
Three Dimensional ◽  
Fused Deposition Modelling ◽  
Future Directions ◽  
Digital Light Processing ◽  
Fused Deposition ◽  
Printing Technique ◽  
3D Printed ◽  
Semi Solid ◽  
Selection Of

Three-dimensional (3D) printing is among the rapidly evolving technologies with applications in many sectors. The pharmaceutical industry is no exception, and the approval of the first 3D-printed tablet (Spiratam®) marked a revolution in the field. Several studies reported the fabrication of different dosage forms using a range of 3D printing techniques. Thermosensitive drugs compose a considerable segment of available medications in the market requiring strict temperature control during processing to ensure their efficacy and safety. Heating involved in some of the 3D printing technologies raises concerns regarding the feasibility of the techniques for printing thermolabile drugs. Studies reported that semi-solid extrusion (SSE) is the commonly used printing technique to fabricate thermosensitive drugs. Digital light processing (DLP), binder jetting (BJ), and stereolithography (SLA) can also be used for the fabrication of thermosensitive drugs as they do not involve heating elements. Nonetheless, degradation of some drugs by light source used in the techniques was reported. Interestingly, fused deposition modelling (FDM) coupled with filling techniques offered protection against thermal degradation. Concepts such as selection of low melting point polymers, adjustment of printing parameters, and coupling of more than one printing technique were exploited in printing thermosensitive drugs. This systematic review presents challenges, 3DP procedures, and future directions of 3D printing of thermo-sensitive formulations.

3D Printing in Dentistry—State of the Art

2020 ◽  
Vol 45 (1) ◽  
pp. 30-40 ◽  
Author(s):  
A Kessler ◽  
R Hickel ◽  
M Reymus
Keyword(s):  
3D Printing ◽  
Clinical Application ◽  
Industrial Revolution ◽  
Rapid Development ◽  
Selective Laser Sintering ◽  
Three Dimensional ◽  
Fused Filament Fabrication ◽  
Digital Light Processing ◽  
Materials Used ◽  
Binder Jetting

SUMMARY Three-dimensional (3D) printing is a rapidly developing technology that has gained widespread acceptance in dentistry. Compared to conventional (lost-wax technique) and subtractive computer numeric controlled methods, 3D printing offers process engineering advantages. Materials such as plastics, metals, and ceramics can be manufactured using various techniques. 3D printing was introduced over three decades ago. Today, it is experiencing rapid development due to the expiration of many patents and is often described as the key technology of the next industrial revolution. The transition to its clinical application in dentistry is highly dependent on the available materials, which must not only provide the required accuracy but also the necessary biological and physical properties. The aim of this work is to provide an up-to-date overview of the different printing techniques: stereolithography, digital light processing, photopolymer jetting, material jetting, binder jetting, selective laser sintering, selective laser melting, and fused filament fabrication. Additionally, particular attention is paid to the materials used in dentistry and their clinical application.

scholarly journals Porous cage-derived nanomaterial inks for direct and internal three-dimensional printing

2020 ◽  
Vol 11 (1) ◽  
Author(s):  
Tangi Aubert ◽  
Jen-Yu Huang ◽  
Kai Ma ◽  
Tobias Hanrath ◽  
Ulrich Wiesner
Keyword(s):  
3D Printing ◽  
Structural Control ◽  
High Surface ◽  
High Surface Area ◽  
Three Dimensional ◽  
Processing Technique ◽  
Advanced Materials ◽  
Host Matrix ◽  
Digital Light Processing ◽  
Three Dimensional Printing

Abstract The convergence of 3D printing techniques and nanomaterials is generating a compelling opportunity space to create advanced materials with multiscale structural control and hierarchical functionalities. While most nanoparticles consist of a dense material, less attention has been payed to 3D printing of nanoparticles with intrinsic porosity. Here, we combine ultrasmall (about 10 nm) silica nanocages with digital light processing technique for the direct 3D printing of hierarchically porous parts with arbitrary shapes, as well as tunable internal structures and high surface area. Thanks to the versatile and orthogonal cage surface modifications, we show how this approach can be applied for the implementation and positioning of functionalities throughout 3D printed objects. Furthermore, taking advantage of the internal porosity of the printed parts, an internal printing approach is proposed for the localized deposition of a guest material within a host matrix, enabling complex 3D material designs.

scholarly journals 3D Printing of Bioceramic Scaffolds—Barriers to the Clinical Translation: From Promise to Reality, and Future Perspectives

Materials ◽  
2019 ◽  
Vol 12 (17) ◽  
pp. 2660 ◽  
Author(s):  
Kang Lin ◽  
Rakib Sheikh ◽  
Sara Romanazzo ◽  
Iman Roohani
Keyword(s):  
3D Printing ◽  
Polymer Matrix Composites ◽  
Three Dimensional ◽  
Processing Parameters ◽  
Matrix Composites ◽  
Large Area ◽  
Digital Light Processing ◽  
Increasing Demand ◽  
New Research ◽  
Porous Bioceramics

In this review, we summarize the challenges of the three-dimensional (3D) printing of porous bioceramics and their translational hurdles to clinical applications. The state-of-the-art of the major 3D printing techniques (powder-based and slurry-based), their limitations and key processing parameters are discussed in detail. The significant roadblocks that prevent implementation of 3D printed bioceramics in tissue engineering strategies, and medical applications are outlined, and the future directions where new research may overcome the limitations are proposed. In recent years, there has been an increasing demand for a nanoscale control in 3D fabrication of bioceramic scaffolds via emerging techniques such as digital light processing, two-photon polymerization, or large area maskless photopolymerization. However, these techniques are still in a developmental stage and not capable of fabrication of large-sized bioceramic scaffolds; thus, there is a lack of sufficient data to evaluate their contribution. This review will also not cover polymer matrix composites reinforced with particulate bioceramics, hydrogels reinforced with particulate bioceramics, polymers coated with bioceramics and non-porous bioceramics.

scholarly journals Grayscale digital light processing 3D printing for highly functionally graded materials

2019 ◽  
Vol 5 (5) ◽  
pp. eaav5790 ◽  
Author(s):  
Xiao Kuang ◽  
Jiangtao Wu ◽  
Kaijuan Chen ◽  
Zeang Zhao ◽  
Zhen Ding ◽  
...  
Keyword(s):  
3D Printing ◽  
Functionally Graded Materials ◽  
Three Dimensional ◽  
Functionally Graded ◽  
Advanced Manufacturing ◽  
4D Printing ◽  
Poor Control ◽  
Graded Materials ◽  
Digital Light Processing ◽  
Direct Fabrication

Three-dimensional (3D) printing or additive manufacturing, as a revolutionary technology for future advanced manufacturing, usually prints parts with poor control of complex gradients for functional applications. We present a single-vat grayscale digital light processing (g-DLP) 3D printing method using grayscale light patterns and a two-stage curing ink to obtain functionally graded materials with the mechanical gradient up to three orders of magnitude and high resolution. To demonstrate the g-DLP, we show the direct fabrication of complex 2D/3D lattices with controlled buckling and deformation sequence, negative Poisson’s ratio metamaterial, presurgical models with stiffness variations, composites for 4D printing, and anti-counterfeiting 3D printing.

scholarly journals Cytocompatibility of 3D printed dental materials for temporary restorations on fibroblasts

2020 ◽  
Author(s):  
Jung-Hyun Park ◽  
Hyun Lee ◽  
Jong-Woo Kim ◽  
Ji-Hwan Kim
Keyword(s):  
3D Printing ◽  
Laser Scanning ◽  
Dental Materials ◽  
Three Dimensional ◽  
Confocal Laser Scanning Microscope ◽  
Confocal Laser ◽  
Control Group ◽  
Digital Light Processing ◽  
3D Printed ◽  
Materials Used

Abstract Background Three-dimensional (3D) printing is widely used in the fabrication of dental prostheses; however, the influence of dental materials used for 3D printing on temporary restoration of fibroblasts in tissues is unclear. Thus, the influence of different dental materials on fibroblasts were investigated. Methods Digital light processing (DLP) type 3D printing was used. Specimens in the control group were fabricated by mixing liquid and powder self-curing resin restoration materials. The temporary resin materials used were Model, Castable, Clear-SG, Tray, and Temporary, and the self-curing resin materials used were Lang dental, Alike, Milky blue, TOKVSO CUREFAST, and UniFast III. Fibroblast cells were cultured on each specimen and subsequently post-treated for analysis. Morphology of the adhered cells were observed using a confocal laser scanning microscope (CLSM) and a scanning electron microscope (SEM). Results CLSM and SEM cell imaging revealed that the 3D printed material group presented better cell adhesion with well-distributed filopodia compared to that in the conventional resin material group. Cell proliferation was significantly higher in the 3D printing materials. Conclusion This indicates that using resins fabricated by 3D printing technology rather than the ones fabricated by self-curing technology is recommended for the fabrication of dental temporary restorations.

scholarly journals Three-Dimensional-Printing of Bio-Inspired Composites

2016 ◽  
Vol 138 (2) ◽  
Author(s):  
Grace X. Gu ◽  
Isabelle Su ◽  
Shruti Sharma ◽  
Jamie L. Voros ◽  
Zhao Qin ◽  
...  
Keyword(s):  
3D Printing ◽  
Material Properties ◽  
Large Scale ◽  
Spider Silk ◽  
Three Dimensional ◽  
Hierarchical Structures ◽  
Building Blocks ◽  
Alternative Methods ◽  
Natural Materials ◽  
Multiple Materials

Optimized for millions of years, natural materials often outperform synthetic materials due to their hierarchical structures and multifunctional abilities. They usually feature a complex architecture that consists of simple building blocks. Indeed, many natural materials such as bone, nacre, hair, and spider silk, have outstanding material properties, making them applicable to engineering applications that may require both mechanical resilience and environmental compatibility. However, such natural materials are very difficult to harvest in bulk, and may be toxic in the way they occur naturally, and therefore, it is critical to use alternative methods to fabricate materials that have material functions similar to material function as their natural counterparts for large-scale applications. Recent progress in additive manufacturing, especially the ability to print multiple materials at upper micrometer resolution, has given researchers an excellent instrument to design and reconstruct natural-inspired materials. The most advanced 3D-printer can now be used to manufacture samples to emulate their geometry and material composition with high fidelity. Its capabilities, in combination with computational modeling, have provided us even more opportunities for designing, optimizing, and testing the function of composite materials, in order to achieve composites of high mechanical resilience and reliability. In this review article, we focus on the advanced material properties of several multifunctional biological materials and discuss how the advanced 3D-printing techniques can be used to mimic their architectures and functions. Lastly, we discuss the limitations of 3D-printing, suggest possible future developments, and discuss applications using bio-inspired materials as a tool in bioengineering and other fields.

scholarly journals Thinking Outside the CAD Box

2012 ◽  
Vol 134 (10) ◽  
pp. 30-35 ◽  
Author(s):  
Hod Lipson
Keyword(s):  
3D Printing ◽  
Computer Aided Design ◽  
Three Dimensional ◽  
Natural World ◽  
New Paradigm ◽  
Challenges And Opportunities ◽  
3D Printers ◽  
Multiple Materials ◽  
Manufacturing Technologies ◽  
Aided Design

This article reviews new 3D printing capabilities for computer-aided design (CAD) engineers. As additive manufacturing technologies such as 3D printing and rapid prototyping become increasingly capable, traditional barriers of resources and skill for manufacturing are all but vanishing. Three-dimensional printers are giving designers unprecedented control over the shape and composition of matter. High-end 3D printers today can combine multiple materials into arbitrary patterns at a resolution close to 10 mm, leading to the ability to create geometry with fidelity and complexity that rivals that of the natural world. The growing accessibility of personal manufacturing tools, such as 3D printers, is democratizing design and enabling new types of designers. The combination of new geometric representations, new design paradigms, and new interfaces leads to new challenges and opportunities in the CAD field as never before. Good design tools are often the hidden enabler of technological innovation; however, balancing the existing performance engine with a new paradigm shift is a difficult but not an impossible task.

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