Filament formation mechanisms in yield-stress fluid-enabled embedded ink writing

Abstract

Embedded ink writing (EIW), an emerging material extrusion-based three-dimensional (3D) printing strategy, has demonstrated great potential for diverse applications. EIW consists of three key components: support bath, ink, and printing conditions. Filament formation in EIW is significantly affected by the coupling effects of these components, which is still unclear. This work aims to fundamentally unveil the filament formation processes and mechanisms within support bath materials with various rheological properties. A broader range of path speed is utilized to ensure the formation of diverse representative filaments from low- and high-viscosity hydrogel inks. By varying the combination of support bath, ink, and printing conditions, ten types of filaments are observed during EIW and their formation mechanisms are explained in detail. Particularly, when designing a support bath for EIW, thixotropic time serves as the baseline to determine the functionality of the bath. A relatively long thixotropic time can facilitate the formation of well-defined filaments. In addition, the support bath’s yield stress decides the allowed maximum path speed. High yield stress is necessary if path speed is targeted in a higher range. Based on the experimental findings, a position-shape-size evaluation system is established and proposed for comprehensively evaluating printed filaments, which is helpful in filtering suitable filaments for EIW. Finally, complex 3D structures including a human nose and a human ear are printed at a high speed within the support bath with suitable rheological properties to bridge the gap between filament formation mechanisms and practical 3D printing applications.