Multi-material 3D Printing Research Articles

Multifunctional and multimaterial contact lenses: tailored solutions for tunable color filtering and tear pH sensing

ABSTRACT Colour vision disorders, pose challenges in perceiving and distinguishing specific colours. To address these challenges, technologies such as colour-filtering glasses and contact lenses have been developed. However, customisation of eyewear for individual patients remains a challenge. This research aims to design multifunctional contact lenses combining colour filtering and pH sensing capabilities for personalised colour vision correction. A pH-responsive, Neutral red dye-doped hydrogel was developed and optimised for the vat photo polymerization-based 3D printing process. A novel in-house multimaterial 3D printing technique was employed for printing lenses exhibiting both colour filtering and pH sensing capabilities. 3D printed samples contained outer radial rings, made from porous and pH-responsive polymer. The optically tunable dye-doped resin was also applied to the central part of the lenses to achieve customised wavelength blockage. The lenses demonstrate potential for customised colour vision correction and pH monitoring of the tear film.

Polysiloxane Inks for Multimaterial 3d Printing of High‐Permittivity Dielectric Elastomers

AbstractDielectric elastomer transducers (DET) are promising candidates for electrically‐driven soft robotics. However, the high viscosity and low yield stress of DET formulations prohibit 3D printing, the most common manufacturing method for designer soft actuators. DET inks optimized for direct ink writing (DIW) produce elastomers with high stiffness and mechanical losses, diminishing the utility of DET actuators. To address the antagonistic nature of processing and performance constraints, principles of capillary suspensions are used to engineer DIW DET inks. By blending two immiscible polysiloxane liquids with a filler, a capillary ink suspension is obtained, in which the ink rheology can be tuned independently of the elastomer electromechanical properties. Rheometry is performed to measure and optimize processibility as a function of filler and secondary liquid fraction. Including polar polysiloxanes as the secondary liquid produces a printed elastomer exhibiting a four‐fold permittivity increase over commercial polydimethylsiloxane. The characterization and multimaterial printing into layered DET devices demonstrates that the immiscible capillary suspension improves the processability of the inks and enhances the properties of the elastomers, enabling actuation of the devices at comparatively low voltages. It is anticipated that this formulation approach will allow soft robotics to harness the full potential of DETs.

Mechanical behaviors of three-dimensional chiral mechanical metamaterials

Chiral and achiral mechanical metamaterials are designed via spherical tiling. The 3D chiral designs show an interesting coupled compression-twisting behavior, while the 3D achiral designs show auxetic behavior. Also, besides the cellular-type chiral and achiral designs, composite-type of each design are created by adding soft matrix to the cellular designs. The designs are fabricated via multi-material 3D printing. Mechanical uni-axial compression experiments are performed on the 3D printed specimens and the experimental results are compared with finite element (FE) simulations. By jointly tailoring the chiral geometry and material combination, the effective mechanical properties and the deformation mechanisms can be tuned in a large range. In addition, a continuum-level material model was developed to predict the constitutive relationship. The results show that the material model can well predict the effective mechanical properties of the chiral 3D mechanical metamaterials.

Design and fabrication of multi-material pneumatic soft gripper using newly developed high-speed multi-material vat photopolymerization 3D printer

Design and fabrication of multi-material pneumatic soft gripper using newly developed high-speed multi-material vat photopolymerization 3D printer

Enhanced Dynamic Impact Resistance of 3D-Printed Continuous Optical Fiber-Reinforced Helicoidal Polylactic Acid Composites.

Characterized by light weight and high strength, composites are widely used as protective materials in dynamic impact loading under extreme conditions, such as high strain rates. Therefore, based on the excellent tensile properties of continuous fiber and the good flexibility and toughness of the bionic spiral structure, this study uses a multi-material 3D printer to incorporate continuous fiber, and then modifies the G-CODE file to control the printing path to achieve the production of a continuous fiber-reinforced Polylactic Acid composite helicoidal (spiral angle 60°) structure (COF-HP). Dynamic behavior under high-strain-rate impact experiments have been conducted using the Split Hopkinson Pressure Bar (SHPB). Stress-strain curves, impact energy curves and high-speed camera photographs with different strain rates at 680 s-1 and 890 s-1 have been analyzed to explore the dynamic process and illustrate the damage evolution. In addition, some detailed simulation models considering the incorporation of continuous optical fiber (COF) and different strain rates have been established and verified for deeper investigations. The results show that the COF does enhance the impact resistance of the laminates. When the porosity is reduced, the maximum stress of the continuous fiber-reinforced composite material is 4~7% higher than that of the pure PLA material. Our findings here expand the application of COF and provide a new method for designing protective materials, which have broad application prospects in the aerospace and automotive industries.

Digital light processing of multi-walled carbon nanotubes-reinforced photosensitive resin composites: Effects on microstructures and mechanical properties

Owing to their great potential to enhance the structural, mechanical, and electrical properties of materials, numerous researchers have dedicated their efforts to manufacturing multi-walled carbon nanotubes (MWCNTs)-reinforced composites via additive manufacturing (AM) to leverage AM's ability to fabricate intricate structural components. However, there is currently limited research on MWCNTs in photosensitive resin (PR) systems processed via a type of vat photopolymerization AM technique - digital light processing (DLP). Additionally, the distribution pattern of MWCNTs in PR systems is still unknown. To address these research gaps, this investigation focuses on fabricating MWCNTs-reinforced PR (MWCNTs-PR) via DLP and studying the effects of MWCNTs content on microstructure characterizations and mechanical properties of MWCNTs-PR. These results show that PR with 0.05 wt% MWCNTs addition exhibits a 25 % increase in elastic modulus and a 2 % increase in bending strength compared to pure PR. To achieve a more uniform distribution of MWCNTs in the PR, a combination of an ultrasonic bath and mechanical stirring was adopted. To further investigate the mechanism behind MWCNTs-enhanced bending resistance, a multi-material layered 3D printing structure was developed. The experimental findings reveal that the 10001 structure yields the highest bending modulus, surpassing the control group by 14.9 %. To validate the bending resistance mechanism attributed to MWCNTs-PR, finite element analysis was conducted.

Algorithmic encoding of adaptive responses in temperature-sensing multimaterial architectures.

We envision programmable matters that can alter their physical properties in desirable manners based on user input or autonomous sensing. This vision motivates the pursuit of mechanical metamaterials that interact with the environment in a programmable fashion. However, this has not been systematically achieved for soft metamaterials because of the highly nonlinear deformation and underdevelopment of rational design strategies. Here, we use computational morphogenesis and multimaterial polymer 3D printing to systematically create soft metamaterials with arbitrarily programmable temperature-switchable nonlinear mechanical responses under large deformations. This is made possible by harnessing the distinct glass transition temperatures of different polymers, which, when optimally synthesized, produce local and giant stiffness changes in a controllable manner. Featuring complex geometries, the generated structures and metamaterials exhibit fundamentally different yet programmable nonlinear force-displacement relations and deformation patterns as temperature varies. The rational design and fabrication establish an objective-oriented synthesis of metamaterials with freely tunable thermally adaptive behaviors. This imbues structures and materials with environment-aware intelligence.

High Volume 3D Printer and Developed of High-Volume Extruders for Gelatin and Liquids

Over the last decade, the development of 3D printing technology has led to both increased interest and availability of these machines. The steady growth and demand have made 3D printing an affordable and consumer-friendly craft. Due to the shrinking barrier-of-entry, the technology is increasingly integrated into wider areas of science and research, as well as the manufacturing industry in general. The demand for individualized medical solutions is continuously expanding in multiple fields, such as medical training and patient-specific surgical guides—exposing a need for further development of these technologies for mainstream applications. The research areas of material science, life science, biotechnology, and medical applications have greatly benefited from the increasing availability of this technology—especially in regard to 3D printing high viscosity substrates which are biological, biocompatible, or bioresorbable. In this area of research and development, mainly micro-extrusion syringe-based systems are used. However, these extruders are limited to the volume of the utilized syringe. The presented work primary objective was to develop a multi-material 3D printer capable of processing substrates with a wide variety of viscosities, with a particular focus on biological-based substrates. The entire project was developed with an open-source mindset—with the intent of furthering future research possibilities within this space. A coreXY printer (0.5x0.5x0.5 m) was developed, including an automatic tool changing mechanism. A peristaltic pump and ink jet extruder were developed and manufactured to improve their processability for additive manufacturing and extrusion of hydrogels and as well as liquids.

Coextrusion of Clay-Based Composites: Using a Multi-Material Approach to Achieve Gradient Porosity in 3D-Printed Ceramics

3D printing of ceramics has started gaining traction in architecture over the past decades. However, many existing paste-based extrusion techniques have not yet been adapted or made feasible in ceramics. A notable example is coextrusion, a common approach to extruding multiple materials simultaneously when 3D-printing thermoplastics or concrete. In this study, coextrusion was utilized to enable multi-material 3D printing of ceramic elements, aiming to achieve functionally graded porosities at an architectural scale. The research presented in this paper was carried out in two consecutive phases: (1) The development of hardware components, such as distinct material mixtures and a dual extruder setup including a custom nozzle, along with software environments suitable for printing gradient materials. (2) Material experiments including material testing and the production of exemplary prototypes. Among the various potential applications discussed, the developed coextrusion method for clay-based composites was utilized to fabricate ceramic objects with varying material properties. This was achieved by introducing a combustible as a variable additive while printing, resulting in a gradient porosity in the object after firing. The research’s originality can be summarized as the development of clay-based material mixtures encompassing porosity agents for 3D printing, along with comprehensive material-specific printing parameter settings for various compositions, which collectively enable the successful creation of functionally graded architectural building elements. These studies are expected to broaden the scope of 3D-printed clay in architecture, as it allows for performance optimization in terms of structural performance, insulation, humidity regulation, water absorption and acoustics.

Heterolayered carbon allotrope architectonics via multi-material 3D printing for advanced electrochemical devices

ABSTRACT 3D printing has become a powerful technique in electrochemistry for fabricating electrodes, thanks to readily available conductive nanocomposite filaments, such as those based on carbon fillers (i.e., carbon nanotubes (CNTs) or carbon black (CB)) within an insulating polymeric matrix like polylactic acid (PLA). Inspired by inorganic heterostructures that enhance the functional characteristics of nanomaterials, we fabricated hetero-layered 3D printed devices based on carbon allotropes using a layer-by-layer assembly approach. The heterolayers were customised through the alternate integration of different carbon allotrope filaments via a multi-material 3D printing technique, allowing for a time-effective method to enhance electrochemical performance. As a first demonstration of applicability, CNT/PLA and CB/PLA filaments were utilised to construct ordered hetero-layered carbon-based electrodes. This contrasts with conventional methods where various carbon species are mixed in the same composite-based filament used for building electrochemical devices. Multi-material 3D-printed carbon electrodes exhibit improved electrochemical performance in energy conversion (e.g., hydrogen evolution reaction or HER) and sensing applications (e.g., ascorbic acid detection) compared to single-material electrodes. This work paves the way for manufacturing advanced 3D-printed heterolayered electrodes with enhanced electrochemical activity through multi-material 3D printing technology.

Multimaterial 3D printing of auxetic jounce bumpers for automotive suspensions

PurposeThe purpose of this study is to evaluate the 3D printability of a multimaterial, fully self-supporting auxetic structure. This will contribute to expanding the application of additive manufacturing (AM) to new products, such as automotive suspensions.Design/methodology/approachAn experimental approach for sample fabrication on a multiextruder 3D printer and characterization by compression testing was conducted along with numerical simulations, which were used to support the design of different auxetic configurations for the jounce bumper.FindingsThe effect of stacking different auxetic cell modules was discussed, and the findings demonstrated that a one-piece printed structure has a better performance than one composed of multiple single modules stacked on top of each other.Research limitations/implicationsThe quality of the 3D printing process affected the performance of the final components and reproducibility of the results. Therefore, researchers are encouraged to further study component fabrication optimization to achieve a more reliable process.Practical implicationsThis research work can help improve the manufacturing and functionality of a critical element of automotive suspension systems, such as the jounce bumper, which can efficiently reduce noise, vibration and harshness by absorbing impact energy.Originality/valueIn previous research, auxetic structures for the application of jounce bumpers have already been suggested. However, to the best of the authors’ knowledge, in this work, an AM approach was used for the first time to fabricate multimaterial auxetic structures, not only by co-printing a flexible thermoplastic polymer with a stiffer one but also by continuously extruding multilevel structures of auxetic cell modules.

Characteristics of Hybrid Pla and Carbon-Pla in Different Laminates Formations

The multi-extruder printer allows to printing of different materials into one product. This paper experimented on multi-material lamination using PLA with rigid characteristics and Carbon-PLA with elastic characteristics. The flexural and shore hardness test was chosen to understand how two different materials affect each other. The results show that the different lamination performances affect the flexural strength. The highest flexural strength from 3 laminations was the CPC of 53.33 MPa, this is 3.03% lower than the PLA only and 37.9% higher than Carbon-PLA only. From the 2 laminate specimens the PC laminates achieved the highest flexural strength of 73.07 MPa, the value is 5.4% higher than the PLA only and 50.01% higher than Carbon-PLA only. The shore hardness value showed no significant changes between the lamination and 1 material only. It was also proved that lamination formation can increase the flexural strength or lead to detrimental results. This finding enables the designer of multi-material 3D printing to consider the formation of materials.

Multimaterial Hydrogel 3D Printing

AbstractIn recent years, hydrogels have emerged as quintessential 3D printing materials. Coupled with their inherent printability, the unique mechanical properties, network structure, and biocompatibility of hydrogels make them ideal for a wide range of 3D printing applications. Also in recent years, the rise of multimaterial 3D printing, an additive manufacturing technology which involves at least two different materials in the fabrication process, has been witnessed. Advanced multimaterial 3D printing protocols have brought the field closer than ever before to a new industrial revolution. In this review, the use of hydrogels in multimaterial 3D printing is investigated. The review is sectioned by discussing three major multimaterial 3D printing methods: direct‐ink‐writing, vat‐switching, and coaxial extrusion. Subsections detail three common domains of multimaterial hydrogel 3D printing: bioprinting, 4D printing, and particle‐polymer composite printing. In the second part of the review, recent advancements in both multimaterial 3D printing hardware and hydrogel inks which are expected to steer the field in exciting new directions are explored. Finally, a case is made for coaxial extrusion and light‐responsive printers being the best choice for multimaterial hydrogel 3D printing in the long run, due to their gradient and greyscale printing capabilities.

Multi-material and parameter-controllable stereolithography 3D printing of graded permittivity composites for high voltage insulators

ABSTRACT Graded permittivity materials have gained significant attention due to their exceptional ability to regulate electric fields. Multi-material stereolithography (SLA) 3D printing has opened up new possibilities for creating such materials. However, conventional SLA printers typically generate graded material using fixed printing parameters and multiple feedstocks with limited differences, resulting in a constrained capacity for modulating the electric field distribution. To address this limitation, we have developed a multi-material, parameter-controllable SLA strategy, enabling us to assign varying printing parameters for each building layer and switch between feedstocks with significant differences. Solid insulators with graded permittivity are optimised through electric field distribution simulations and subsequently manufactured using our innovative multi-material SLA approach. A 4-layered graded insulator effectively decreases the maximum electric field strength from 82.5–30.8 kV/mm. Both flashover tests and partial discharge signals confirm that graded insulators outperform homogeneous ones in electrical insulation.

Amoeboid soft robot based on multi-material composite 3D printing technology

A core–shell structured, amoeba-like, magnetically controlled soft robot is proposed for 3D printing using magnetically controlled smart materials and silicone materials. The purpose of this robot is to overcome the limitations of existing soft robot kinematic mechanisms that rely on the elastic deformation of flexible materials. The printability of the magnetically controlled smart material was verified through rheological tests. The effect of different component ratios on the rheological properties of the material was investigated and a suitable material ratio for printing was selected by adjusting the amount of SiO2 in the silicone and conducting rheological tests. Mechanical simulation was used to select and optimize the design of the amoeboid soft robotic shell structures. Printing was then used to verify the stability of the shell structures. The self-supporting capability of the magnetically controlled smart materials was investigated under different magnetic field strengths. To solve the problem of the phase of the magnetron smart material and the silicone material, the composite printing of the two materials was accomplished by adjusting the printing process. Soft robots mimicking amoebas were then printed and fabricated. The magnetron array-based driving method is proposed, and the magnetic field of the array used to drive the amoeba-like soft robot is constructed. The magnetic field of the array surface was then simulated under several different driving modes. Based on the simulation results, a suitable driving mode was selected. Using the material mechanism of the magnetron-only material sol–gel transformation, the pseudopod extension gait of the amoeba-like soft robot was designed, and the localized deformation of the amoeba-like soft robot was realized.This paper leveraged the distinctive properties of magnetorheological smart materials to devise and fabricate an integrated 3D-printed soft robot. Such magnetorheological smart materials can function as both the supporting framework for hollow cavities and the propelling substance for the robot. During the course of this process, we investigated material properties pertinent to 3D printing and refined the design of the robot's structure and driving mechanism.

Cost-effective fabrication of customized LTCC devices with multilayer using multi-material 3D printing

Low-temperature co-fired ceramic (LTCC) devices have been widely used in the defense, automotive, medical, and aerospace industries. However, the traditional manufacturing process of LTCC devices is hardly suitable for cost-effective, fast design and customization requirements. In this work, we propose a multi-material integrated 3D printing technology for LTCC. LTCC slurry was configured using homemade borosilicate glass powder and Al2O3 powder, and the influence of printing parameters on the printed effect was investigated. The shrinkage of the ceramics sintered at 850 °C for 15 min was 14.82 ± 0.47 % in the XY direction and 13.7 ± 0.26 % in the Z direction, comparable to that of commercial LTCC. Wireless sensing multilayer LED circuit and passive humidity sensor were fabricated, where the sensor with a sensitivity of 0.132 MHz/%RH. These cases demonstrate that the proposed technology can rapidly produce LTCC devices and meet the demand for custom LTCC devices in high-end manufacturing.

Design and analysis of multi-material structures of 3D printed implants of mandible

Significant advances in 3D printing technology have paved the way for improvements in the integrity and biological characteristics of polymer implants. The principal objective of this research is the construction of a heterogeneous implant structure using a multi-material approach and 3D printing. Due to their advantageous strength-to-weight ratio, biocompatible polymers have an increasing application in the field of medicine. The osteo-integration process, in which implants bind to the bone over time, can be made more effective by incorporating these materials into implants. In this work, we focused especially on analyzing the strength and integrity of polymer material implants that were created using a combination of different materials, and their stress distribution, and the deformation of these multi-material structures when they were subjected to physiological loading through finite element analysis. The evidence from the frontal bite condition has led to some fascinating conclusions. The variations in stress were observed in homogenous structures, with values ranging from 37.42 MPa for the TPU to 41.07 MPa for the PETG. In contrast, stress distributions in multi-material constructions ranged from 52.31 MPa (in the case of TPU +TPU) to 73.55 MPa (in the case of PLA+ PCL). Similarly, the maximum deformation in homogeneous constructions ranged from 0.81mm (PLA) to 6.85mm (PCL). The deformation of multi-material structures composed of several different materials ranged from 0.68mm (PLA+ PLA) to 5.74 mm (PCL+PCL).These findings provide conclusive evidence that multi-material architectures have a considerable impact on known stress and strain levels. Particularly noteworthy is the fact that the combination of PLA+PLA and PLA+PETG displayed deformation that was equivalent to that of the intact bone model while having lower stress levels. The results of this study provide useful information that can be used to select optimal multi-material combinations that can be 3D printed for implants.

A 3D Printing‐Enabled Artificially Innervated Smart Soft Gripper with Variable Joint Stiffness

AbstractThe manufacturing industry has witnessed advancements in soft robotics, specifically in robotic grippers for handling fragile or irregular objects. However, challenges remain in balancing shape compliance, structural rigidity, weight, and sensor integration. To address these limitations, a 3D‐printed multimaterial gripper design is proposed. This approach utilizes a single, nearly fully automated 3D printing process to create a universal gripper with almost no assembly work. By processing functional polymer, polymer nanocomposite, and metal wire simultaneously, this technique enables multifunctionality. The gripper achieves different gripping configurations by adjusting joint stiffness through Joule heating of conductive polylactic acid material, ensuring shape conformance. Embedded metal wires, created using an in‐house wire embedding technique, form reliable high‐current‐loading interconnections for the conductive joints acting as the heater. Additionally, an integrated soft sensor printed in thermoplastic polyurethane (TPU) and conductive TPU detects compression levels and discerns handled samples. This study showcases the potential of 3D multimaterial printing for on‐demand fabrication of a smart universal gripper with variable stiffness and integrated sensors, benefiting the automation industry. Overall, this work presents an effective strategy for designing and fabricating integrated multifunctional structures using soft, rigid, and conductive materials, such as polymer, polymer nanocomposite, and metal through multimaterial 3D printing.

Personalized 3D Printed Eye Gear for Microscopic Surgeons Amidst and beyond COVID-19.

The COVID-19 pandemic underscored the need for enhanced protective measures for healthcare workers, particularly surgeons, who face a heightened risk of exposure to infectious aerosols. However, conventional eye protection equipment such as face shields, goggles, or glasses often leads to ergonomic discomfort and a reduced field of view (FOV), impeding surgeons' ability to perform microsurgical procedures with precision and ease. To address these limitations, this study aimed to develop personalized 3D-printed eye gear for microscopic surgeons based on facial anthropometry data. 3D scanning was employed to obtain facial data from ten neurosurgery residents. Utilizing computer-aided designing, eye gears tailored to the unique facial features of each participant were developed. Finite element analysis-based contact simulation was used to assess the pressure exerted by the eye gear. Multi-material 3D printing was employed to fabricate the personalized eye gear. Participants, while donning the eye gear, engaged in simulation-based micro suturing tasks at various magnifications of the operating microscope, and marked the FOV range. They provided feedback scores (1-10) on the effectiveness of the eye gear through a Likert scale questionnaire (Q1-Q8). Finite element analysis demonstrated uniform strain distribution on the face, indicating that the edges of the customized eye gear fit exactly to the user's face. The average scores for the questionnaire Q1 to Q8 ranged from 6.8 to 8.5, with an overall mean score of 7.6. This indicates that the developed eye gear was simple to use and did not cause any discomfort. Additionally, the average reduction in the FOV was only 10.93% across the different operating microscope magnifications. These findings highlight eye gear's potential to alleviate discomfort and enhance precision in microscopic surgeries. Consequently, personalized 3D-printed eye gear offers a promising solution for providing surgeons with a safe environment while preserving the benefits of the operating microscope.

Hybrid Multimaterial 3D Printing Using Photocuring-While-Dispensing.

Three-dimensional (3D) printing methods, such as vat photopolymerization (VPP) and direct-ink-writing (DIW) processes, are known for their high-resolution and multimaterial capabilities, respectively. Here a novel hybrid 3D printing technique that combines the strengths of VPP and DIW processes to achieve multimaterial and high-resolution printing of functional structures and devices, is presented. The method involves dispensing liquid-like materials via syringes into a photocurable matrix material and subsequently using a Galvano mirror-controlled laser beam to selectively photocure the dispensed material trace or the matrix material surrounding the trace. The laser beam scanning and syringe dispensing are synchronized with a set delay to control liquid diffusion and in situ fixture. The versatility of the method is demonstrated by fabricating intricate 3D ant and wheel prototypes using various materials available for VPP and DIW technologies. The proposed photocuring-while-dispensing strategy offers advantages over conventional multimaterial 3D printing methods, such as integrating materials regardless of photocurability and viscosity, and fabricating heterogeneous structures with complex geometries and high resolution. With its principle demonstrated, this multimaterial 3D printing process will open up a wide range of potential applications with diverse functionalities and materials.