Digital Light Processing 3D Printing Research Articles

Microarray Platforms Based on 3D Printing.

This paper introduces an innovative method for the fabrication and infusion of microwell arrays based on digital light processing (DLP) 3D printing. A low-cost DLP 3D printer is employed to fabricate microstructures rapidly with a broad dynamic range while maintaining high precision and fidelity. We constructed microwell arrays with varying diameters, from 200 to 2000 μm and multiple aspect ratios, in addition to microchannels with widths ranging from 45 to 1000 μm, proving the potential and flexibility of this fabrication method. The superimposition of parallel microchannels onto the microwell array, facilitated by positive or negative pressure, enabled the transfer of liquid to the microwells. Upon removal of the microchannel chip, a dispensed microdroplet array was obtained. This array can be modulated by adjusting the volume of the microwells and the inflow fluid. The filled microwell array allows chip-to-chip dispensing to the microreactor array through binding and centrifugation, facilitating multistep and multireagent assays. The 3D printing approach also enables the fabrication of intricate cavity designs, such as micropyramid arrays, which can be integrated with parallel microchannels to generate spheroid flowcells. This device demonstrated the ability to generate spheroids and manipulate their environment. We have successfully utilized precise modulation of spheroids size and performed parallel drug dose-response assays to evaluate its effectiveness. Furthermore, we managed to execute dynamic drug combinations based on a compact spheroids array, utilizing two orthogonal parallel microchannels. Our findings suggest that both the combination and temporal sequence of drug administration have a significant impact on therapeutic outcomes.

Three-Dimensional-Printed GelMA-KerMA Composite Patches as an Innovative Platform for Potential Tissue Engineering of Tympanic Membrane Perforations.

Tympanic membrane (TM) perforations, primarily induced by middle ear infections, the introduction of foreign objects into the ear, and acoustic trauma, lead to hearing abnormalities and ear infections. We describe the design and fabrication of a novel composite patch containing photocrosslinkable gelatin methacryloyl (GelMA) and keratin methacryloyl (KerMA) hydrogels. GelMA-KerMA patches containing conical microneedles in their design were developed using the digital light processing (DLP) 3D printing approach. Following this, the patches were biofunctionalized by applying a coaxial coating with PVA nanoparticles loaded with gentamicin (GEN) and fibroblast growth factor (FGF-2) with the Electrohydrodynamic Atomization (EHDA) method. The developed nanoparticle-coated 3D-printed patches were evaluated in terms of their chemical, morphological, mechanical, swelling, and degradation behavior. In addition, the GEN and FGF-2 release profiles, antimicrobial properties, and biocompatibility of the patches were examined in vitro. The morphological assessment verified the successful fabrication and nanoparticle coating of the 3D-printed GelMA-KerMA patches. The outcomes of antibacterial tests demonstrated that GEN@PVA/GelMA-KerMA patches exhibited substantial antibacterial efficacy against Staphylococcus aureus, Pseudomonas aeruginosa, and Escherichia coli. Furthermore, cell culture studies revealed that GelMA-KerMA patches were biocompatible with human adipose-derived mesenchymal stem cells (hADMSC) and supported cell attachment and proliferation without any cytotoxicity. These findings indicated that biofunctional 3D-printed GelMA-KerMA patches have the potential to be a promising therapeutic approach for addressing TM perforations.

Evolution of Self‐Assembled Lignin Nanostructure into Dendritic Fiber in Aqueous Biphasic Photocurable Resin for DLP‐Printing

AbstractThe design of lignin nanostructures where interfacial interactions enable enhanced entanglement of colloidal networks can broaden their applications in hydrogel‐based materials and light‐based 3D printing. Herein, an approach for fabricating surface‐active dendritic colloidal microparticles (DCMs) characterized by fibrous structures using nanostructured allylated lignin is proposed for the development of lignin‐based photocurable resins. With allyl‐terminated surface functionality of 0.61 mmol g−1, the entanglement between lignin‐DCM fibrils with a size of 1.4 µm successfully produces only lignin‐based hydrogels with structural integrity through photo‐crosslinking. The colloidal network of lignin dendricolloids reinforces the poly(ethylene glycol) (PEG) hydrogels during a digital light processing (DLP) 3D printing process by generating bicontinuous morphologies, resulting in six‐fold increases in toughness values with respect to the neat PEG hydrogel. The dual effectiveness of photoabsorption and free‐radical reactivity of lignin‐DCMs allow the light‐patterning of rather dilute PEG hydrogels (5–10%) with high geometric fidelity and structural complexity via DLP 3D printing. This study demonstrates a green and effective strategy for the design of 1D lignin‐DCMs that increases the versatility of the nanostructured biopolymer, opening up numerous opportunities for formulating functional hydrogels with robust structure‐property correlations.

AutoML-driven diagnostics of the feeder motor in fused filament fabrication machines from direct current signals

AbstractPart defects in additive manufacturing are more frequent compared to machining or molding. Failures can go unnoticed for hours, wasting resources and extending process cycle times. This paper describes a Machine Learning based method for automated sensing of onset failure in additive manufacturing machinery. Investigations are conducted on a Fused Filament Fabrication (FFF) 3D printer, and the same methods are then applied to a digital light processing 3D printer. The investigation focuses on signal-based analysis, specifically passive sensing of stepper motors relating DC current measurements to the torque on a stepper, as opposed to any active acoustic interrogation of the part. Passive methods are used to characterize the loading on a feeder stepper in an FFF machine, forming a model that can identify early signs of filament-based failure with 85.65% 10-fold cross-validation accuracy. Efforts show filament breakage can be detected minutes before material runout would cause a defect, allowing ample time to pause, correct, or control the print. The machine learning pipeline was not naively conceived but optimized through automated machine learning.

Investigation of sound absorption on a polymeric acoustic metamaterial using 3D printing process

AbstractThis paper presents the design and characterization of DENORMS (Designs for Noise‐Reducing Materials and Structures) cell‐based acoustic metamaterial developed using a 3D printing technique. The metamaterial's acoustic absorption properties were investigated through experimental testing and numerical simulations. The experimental testing of the acoustic metamaterial was conducted in an impedance tube using a two‐microphone method. The numerical simulations were carried out using a thermoviscous module. The simulations allowed for a deeper understanding of the influence of geometric parameters on the absorption coefficient, providing valuable insights for optimizing the design. It was observed that upon increasing the spherical diameter while maintaining the same cylindrical diameter and cylindrical length resulted in an increase in the absorption coefficient throughout the frequency range. It was also observed that upon increasing the cylindrical diameter, there was a significant decrement of absorption coefficient, and upon increasing the length of the cylinder, there was a shift of response toward lower frequency. The augmentation in cell count from 9 to 24 led to a rise in the absorption coefficient and a shift of the response toward lower frequencies. The findings highlight the significance of photopolymer 3D printing in tailoring complex geometries for enhanced performance of the acoustic metamaterial.Highlights Photopolymeric resin used for DENORMS cell‐based acoustic metamaterial. High cleanability and accuracy of digital light processing 3D printing technique. Usage of thermoviscous model for simulation of sound absorption behavior. Use of two microphone impedance tube to determine sound absorption coefficient. Geometric parameters significantly affect the absorption coefficient.

Experimental investigation and optimization of process parameters on digital light processing (DLP) 3D printing process based on Taguchi-grey relational analysis

Additive manufacturing technology, specifically Digital Light Processing (DLP), offers a unique approach to fabricating intricate objects without the need for traditional molds or machining. The technique described entails the incremental construction of layers through the curing process polymer, facilitated by a projection light source. Digital Light Processing 3D printing is particularly suited for creating complex structures with small cross-sections, requiring high surface polish and durability. In this study, DLP-printed test coupons were produced using an Ultraviolet-sensitive resin, and the investigation focused on examining the impact of surface quality and toughness, adhering to guidelines outlined by the ASTM specifications. To optimize the DLP printing process, Taguchi and Grey relational optimization techniques were employed to find the best values for multiple factors. The parameters considered in this study were speed, layer thickness, orientation, and pattern type. By employing these techniques, the optimal parameters were identified as follows: The printing process is conducted at a speed of 3 mm per second, with each layer being 0.05 mm thick and the orientation of the printed object is set at 90 degrees, and the pattern employed is of the square type. Experimental results revealed that utilizing these parameters yielded a surface roughness of 2.58 µm and an impact strength of 9.1J. The results showed that the Grey relational grade improved from 0.6244 to 0.7974, with a deviation of 0.173 and 27.71%, indicating a significant enhancement in the optimization process. Additionally, contour plots depicting the relationships between speed and orientation, speed and layer thickness, and orientation and layer thickness were generated for surface roughness, impact strength, and the Grey relational grade. This research offers valuable insights into optimizing DLP 3D printing processes to achieve enhanced surface quality, toughness, and material efficiency while reducing costs and production time.

Multiscale design and digital light processing preparation of high-strength SiOC ceramic metastructures for tuning microwave absorption properties

Silicon oxycarbide (SiOC) ceramics have been used to fabricate microwave-absorbing metastructures, demonstrating impressive absorption capabilities. However, SiOC ceramic metastructures with excellent performance require simple fabrication processes and appropriate mechanical and electromagnetic properties. In this study, a solvent-free photosensitive polysiloxane preceramic was developed by blending methoxy/hydroxy polysiloxanes with acrylates, with a ceramic yield of over 60% after curing using a novel two-step ultraviolet (UV)/thermal method. The composition and microstructure of SiOC ceramics can be designed by controlling the preceramic composition. Dense, crack-free gyroid-shellular shaped triple periodic minimal surface (GS-TPMS) electromagnetic metastructures were fabricated using digital light processing (DLP) 3D printing technology. By designing the porosity of the GS-TPMS structure to 51%, an effective absorption bandwidth that covers the X-band can be achieved at a thickness of 3.1 mm. The honeycomb structure, with a geometric density of 0.69 g/cm3, exhibited a high compressive strength of 107.05 MPa. This paper presents an efficient approach for the prompt and customized fabrication of lightweight ceramic metastructures with outstanding microwave absorption properties.

Flame Retardant Additives in Polylactic Acid (PLA) Photopolymer Resin for 3D Printing Digital Light Processing (DLP)

Digital light processing (DLP) technology has been developed based on stereolithography (SLA) 3D-printing principle. The biodegradable and low-cost polylactic-acid (PLA) has so far been used as polymeric material for photopolymer resin in SLA and DLP. To achieve functional SLA-processed product, the properties of such PLA has been improved, with the aim to make it flame retardant, less viscous, and having light transmittance characteristics. In this study, the liquid raw PLA photopolymer was changed by adding different contents of Ammonium Phosphate (APP), melamine cyanurate (MCA), Aluminum Tri-hydroxide (Al2O3) and Nano-silicon dioxide (SiO2) additives. The solid PLA nanocomposite specimens were printed by using DLP device according to the standard geometry for burning test UL-94 to evaluate its flame-retardant property. In addition, the printing product and residue after burning test was analyzed for their morphological characteristic by using SEM. The results showed that the low weight fraction of MCA showed excellent performance. PLA/MCA successfully kept green body form until the sintering temperature of stainless steel was achieved. It can become a reference for application DLP 3D printing products in the casting and sintering process.

Digital light processing 3D printing of microfluidic devices targeting high-pressure liquid-phase separations.

This paper focuses on 3D printing using digital light processing (DLP) to create microchannel devices with inner diameters of100, 200, and 500 µm and cater flow-through applications within the realm of analytical chemistry, in particular high-pressure liquid chromatographic separations. Effects of layer thickness and exposure time on channel dimensions and surface roughness were systematically investigated. Utilizing a commercially accessible 3D printer and acrylate resin formulation, we fabricated 100-500 µm i.d. squared and circular channel designs minimizing average surface roughness (< 20%) by applying a 20-µm layer thickness and exposure times ranging from 1.1 to 0.7s. Pressure resistance was measured by encasing microdevices in an aluminum chip holder that integrated flat-bottom polyetheretherketon (PEEK)nanoports allowing to establish the micro-to-macro interface to the HPLC instrument. After thermal post-curing and finetuning the clamping force of the chip holder, a maximum pressure resistance of 650bar (1.5% RSD) was reached (n = 3). A polymer monolithic support structure was successfully synthesized in situ with the confines of a 500 µm i.d. 3D printed microchannel. A proof-of-concept of a reversed-phase chromatographic gradient separation of intact proteins is demonstrated using an aqueous-organic mobile-phase with isopropanol as organic modifier.

Digital light 3D printing of artificial bone with star-shaped polycaprolactone-based polyurethane acrylate

Advanced medical materials and manufacturing technologies are highly in demand in artificial bones. Herein, a four-arm star-shaped polycaprolactone polyurethane acrylate (FPCLA) was designed and synthesized. The photosensitive character of FPCLA contributed to the rapid prototyping and personalized customization under digital light processing (DLP) 3D printing technology. The FPCLA was prepared by introducing unsaturated double bonds into polycaprolactone tetraethyl alcohol (PCLT). We characterized the physico-chemical properties of the material through FTIR, H-NMR, GPC, DSC and SEM. Cell behaviors on material were observed in vitro. In addition, we employed a DLP 3D printer to evaluate the feasibility of FPCLA to fabricate artificial bone model. The photocuring star polycaprolactone was confirmed in detail by detection method. SEM analyses demonstrated that FPCLA has good tenacity. The material can be used to fabricated artificial bone with a diameter of 3.02 mm at its narrowest by DLP 3D printing technology. The cell survival rates of CCK-8 and Live/Dead fluorescence staining experiments were both above 90%, which indicated safety and feasibility of such new-generation artificial bone made of synthetic polymers.

Evonik launches new flame retardant photopolymer resin and high-performance phosphate methacrylate

On February 8, 2024, Evonik announced the launch of a new photopolymer resin that is claimed to be both flame retardant and mechanically durable when cured. Designed for use with DLP (digital light processing) 3D printers, INFINAM® FR 4100L is claimed to be pourable at room temperature and printable and further processable to achieve a desired surface feel.

Digital Light Processing 4D Printing of Poloxamer Micelles for Facile Fabrication of Multifunctional Biocompatible Hydrogels as Tailored Wearable Sensors.

The lack of both digital light processing (DLP) compatible and biocompatible photopolymers, along with inappropriate material properties required for wearable sensor applications, substantially hinders the employment of DLP 3D printing in the fabrication of multifunctional hydrogels. Herein, we discovered and implemented a photoreactive poloxamer derivative, Pluronic F-127 diacrylate, which overcomes these limitations and is optimized to achieve DLP 3D printed micelle-based hydrogels with high structural complexity, resolution, and precision. In addition, the dehydrated hydrogels exhibit a shape-memory effect and are conformally attached to the geometry of the detection point after rehydration, which implies the 4D printing characteristic of the fabrication process and is beneficial for the storage and application of the device. The excellent cytocompatibility and in vivo biocompatibility further strengthen the potential application of the poloxamer micelle-based hydrogels as a platform for multifunctional wearable systems. After processing them with a lithium chloride (LiCl) solution, multifunctional conductive ionic hydrogels with antifreezing and antiswelling properties along with good transparency and water retention are easily prepared. As capacitive flexible sensors, the DLP 3D printed micelle-based hydrogel devices exhibit excellent sensitivity, cycling stability, and durability in detecting multimodal deformations. Moreover, the DLP 3D printed conductive hydrogels are successfully applied as real-time human motion and tactile sensors with satisfactory sensing performances even in a -20 °C low-temperature environment.

Rapid tooling for rubber extrusion molding by digital light processing 3D printing with dual curable vitrimers

AbstractFor the manufacture of extrusion dies, three‐dimensional (3D) printing with photopolymers offers numerous advantages including flexibility, high surface quality, decent build speed, low costs and a reduced amount of waste. However, the majority of photocurable resins used in vat photopolymerization 3D printing rely on acrylates, which entail 3D‐printed objects with poor mechanical properties. In particular, the high brittleness limits their application in rapid tooling, for which tough materials with high glass transition temperatures (Tg) are required. In the present study, we highlight the use of dual curable acrylate‐epoxy resins with dynamic covalent bonds for the direct fabrication of extrusion dies. During digital light processing (DLP) 3D printing the acrylate network is formed, whose toughness and thermal stability are significantly enhanced by the thermoactivated formation of a second network. By following a postbaking procedure, aminoglycidiyl monomers are cured with an anhydride hardener bearing bulky norbornene groups yielding interpenetrating polymer networks with a Tg &gt; 100°C. The tertiary amine groups present in the structure of the aminoglycidyl derivatives do not only accelerate the ring‐opening reaction but also act as internal catalysts and activate bond exchange reactions between free –OH groups and ester moieties available in the photopolymer. This is confirmed by rheometer studies showing a distinctive stress relaxation at elevated temperature and giving rise to a possible reprocessability of the 3D‐printed dies. With a selected resin formulation, a set of dies is printed by DLP 3D printing, with which a highly filled rubber compound is successfully extruded. The results clearly show that dual curable resins with dynamic covalent bonds are a promising class of material for rapid tooling and pave the way towards a customized and convenient fabrication of extrusion dies for rubber processing.

Effect of functionality of diluents on digital light processing (DLP) based three‐dimensional (3D) printing of UV‐curable bisphenol A‐based epoxy acrylate resin

AbstractDigital light processing (DLP) based three‐dimensional (3D) printing technology which uses photocurable resin has been a center of interest due to its printing accuracy and printing speed. In our research, we have synthesized and modified the bisphenol A‐based epoxy acrylate resin for the DLP 3D printer having a printing accuracy of 50 μm. As the viscosity plays an important role in printing accuracy, the resin was modified with mono‐functional, di‐functional, tri‐functional, and combination of di‐tri functional acrylate diluents as well as with photoinitiator to achieve the desired level of viscosity. The process parameters like curing time and intensity were optimized using the DLP 3D printer. The uncured and UV‐cured samples were characterized using FTIR‐ATR, 1HNMR, UV–VISIBLE, and TGA techniques. The analysis of the uncured and UV‐cured samples was carried out using viscosity, gel content, water absorption, and chemical resistance test. The mechanical properties of the UV‐cured samples were determined using hardness and tensile strength test. The 3D‐printed samples were observed under high‐resolution microscope to confirm the printing quality and resolution. The resulting outcome confirmed that the proper selection of diluents is an important parameter for achieving the good quality and resolution of samples printed using the DLP 3D printer technology.Highlights Synthesis and modification of UV‐curable resin Selection of diluents for controlling the processablility of UV‐curable resin Optimization of process parameters for DLP based 3D printer 3D printing of samples having good quality, resolution and feature size.

DLP‐Printable Porous Cryogels for 3D Soft Tactile Sensing

AbstractThree‐Dimensional (3D) printed porous materials hold the potential for various soft sensing applications due to their remarkable flexibility, low density, and customizable geometries. However, developing versatile and efficient fabrication methods is crucial to unlock their full potential. A novel approach is introduced by combining Digital Light Processing (DLP) 3D printing and freeze‐drying to manufacture deformable cryogels featuring intricate morphologies. Photocurable hydrogels based on Poly(3,4‐ethylenedioxythiophene)Polystyrene sulfonate (PEDOT:PSS), Polyethylene glycol Diacrylate (PEGDA) and Ethylene Glycol (EG) are successfully printed and lyophilized. In this way, porous cryogels with tailorable properties are achieved. Microporosity varies from 68% to 96%, according to the chemical composition. Ultra‐soft cryogels with a compressive modulus of 0.13MPa are fabricated by adding a reactive diluent. As a result of the cryogelation process, which effectively removes water from the hydrogels, microporous structures with details as fine as 100 µm are obtained. The achieved freedom of design is exploited to fabricate resistive force sensors with a honeycomb lattice morphology. The sensitivity and the working range of the sensors can be tailored by tuning the size of the cells, paving the way for sensors with programmable architectures that can meet diverse requirements.

DLP Fabrication of Multiple Hierarchical Biomimetic GelMA/SilMA/HAp Scaffolds for Enhancing Bone Regeneration.

Severe bone defects resulting from trauma and diseases remain a persistent clinical challenge. In this study, a hierarchical biomimetic microporous hydrogel composite scaffold was constructed by mimicking the hierarchical structure of bone. Initially, gelatin methacrylamide (GelMA) and methacrylic anhydride silk fibroin (SilMA) were synthesized, and GelMA/SilMA inks with suitable rheological and mechanical properties were prepared. Biomimetic micropores were then generated by using an aqueous two-phase emulsification method. Subsequently, biomimetic microporous GelMA/SilMA was mixed with hydroxyapatite (HAp) to prepare biomimetic microporous GelMA/SilMA/HAp ink. Hierarchical biomimetic microporous GelMA/SilMA/HAp (M-GSH) scaffolds were then fabricated through digital light processing (DLP) 3D printing. Finally, in vitro experiments were conducted to investigate cell adhesion, proliferation, and inward migration as well as osteogenic differentiation and vascular regeneration effects. In vivo experiments indicated that the biomimetic microporous scaffold significantly promoted tissue integration and bone regeneration after 12 weeks of implantation, achieving 42.39% bone volume fraction regeneration. In summary, this hierarchical biomimetic microporous scaffold provides a promising strategy for the repair and treatment of bone defects.

3D printed microfluidic valve on PCB for flow control applications using liquid metal

Direct 3D printing of active microfluidic elements on PCB substrates enables high-speed fabrication of stand-alone microdevices for a variety of health and energy applications. Microvalves are key components of microfluidic devices and liquid metal (LM) microvalves exhibit promising flow control in microsystems integrated with PCBs. In this paper, we demonstrate LM microvalves directly 3D printed on PCB using advanced digital light processing (DLP). Electrodes on PCB are coated by carbon ink to prevent alloying between gallium-based LM plug and copper electrodes. We used DLP 3D printers with in-house developed acrylic-based resins, Isobornyl Acrylate, and Diurethane Dimethacrylate (DUDMA) and functionalized PCB surface with acrylic-based resin for strong bonding. Valving seats are printed in a 3D caterpillar geometry with chamber diameter of 700 µm. We successfully printed channels and nozzles down to 90 µm. Aiming for microvalves for low-power applications, we applied square-wave voltage of 2 Vpp at a range of frequencies between 5 to 35 Hz. The results show precise control of the bistable valving mechanism based on electrochemical actuation of LMs.

Direct 4D printing of ceramics driven by hydrogel dehydration

4D printing technology combines 3D printing and stimulus-responsive materials, enabling construction of complex 3D objects efficiently. However, unlike smart soft materials, 4D printing of ceramics is a great challenge due to the extremely weak deformability of ceramics. Here, we report a feasible and efficient manufacturing and design approach to realize direct 4D printing of ceramics. Photocurable ceramic elastomer slurry and hydrogel precursor are developed for the fabrication of hydrogel-ceramic laminates via multimaterial digital light processing 3D printing. Flat patterned laminates evolve into complex 3D structures driven by hydrogel dehydration, and then turn into pure ceramics after sintering. Considering the dehydration-induced deformation and sintering-induced shape retraction, we develop a theoretical model to calculate the curvatures of bent laminate and sintered ceramic part. Then, we build a design flow for direct 4D printing of various complex ceramic objects. This approach opens a new avenue for the development of ceramic 4D printing technology.

Preparation of excellent performance ZTA ceramics and complex shaped components using digital light processing 3D printing technology

Complex cellular structured Al2O3 ceramics is difficult to fabricate due to its poor toughness. To overcome this limitation, La2O3 and ZrO2 were introduced into Al2O3 ceramics in digital light processing (DLP) 3D printing. The toughening of ZrO2 and in-situ formation of platelet grains by La2O3 addition dramatically increased the performance of printed ceramics (flexural strength of 556.6 MPa, fracture toughness of 6.94 MPa·m1/2, Vickers hardness of 18.88 GPa, and an apparent porosity of 0.09%), which exceeds most of those fabricated by traditional process. Furthermore, four different cellular structures were successfully fabricated with a Diamond-structure being the best (compressive strength of 40.62 MPa, Young’s modulus of 2.41 GPa, energy absorption of 0.45 MJ/m3, cellular density of 1.70 g/cm3, and specific strength of 23.83 MPa/(g/cm3)). This study presents a novel strategy for using DLP 3D printing technology in the fabrication of lightweight, high-strength and complex shaped ceramic components. It aims to expedite the rapid application of DLP 3D printing technology in various fields such as aerospace and medical.

Antiviral and Antibacterial 3D-Printed Products Functionalised with Poly(hexamethylene biguanide).

Infection prevention and public health are a vital concern worldwide, especially during pandemics such as COVID-19 and seasonal influenza. Frequent manual disinfection and use of chemical spray coatings at public facilities are the typical measures taken to protect people from coronaviruses and other pathogens. However, limitations of human resources and coating durability, as well as the safety of disinfectants used are the major concerns in society during a pandemic. Non-leachable antimicrobial agent poly(hexamethylene biguanide) (PHMB) was mixed into photocurable liquid resins to produce novel and tailor-made covers for public facilities via digital light processing, which is a popular 3D printing technique for satisfactory printing resolution. Potent efficacies of the 3D-printed plastics were achieved in standard antibacterial assessments against S. aureus, E. coli and K. pneumoniae. A total of 99.9% of Human coronavirus 229E was killed after being in contact with the 3D-printed samples (containing the promising PHMB formulation) for two hours. In an eight-week field test in Hong Kong Wetland Park, antibacterial performances of the specially designed 3D-printed covers analysed by environmental swabbing were also found to be satisfactory. With these remarkable outcomes, antimicrobial products prepared by digital light processing 3D printing can be regarded as a reliable solution to long-term infection prevention and control.