Printing Accuracy Research Articles

Minimizing Polymer Curl Distortion and Heat Impact to Improve Digital Light Processing Printing Accuracy via Subdivision Method

Curl distortion has been a persistent challenge for vat photopolymerization‐based printing technology such as digital light processing (DLP), leading to structural deformation and print failures. This study presents a new approach to mitigate curling distortion and heat effects during DLP printing by dividing the printing layer image into sequential subimages, using a breadth‐first search algorithm. The progressive curing process, resembling a ripple pattern, results in a significant improvement in printing accuracy. The deviation is reduced tenfold when the layer image is divided into subimages with 10 pixels for a 32 mm diameter disc. Additionally, subdivision strategy helps to reduce the heat effect during photopolymerization, as monitored in situ by a long‐wave infrared camera. The successful reduction of residual stress using the subdivision strategy results in a 75% improvement in the mechanical performance of the printed products. The simple adoption of subdivision strategy in practical 3D printing applications is also demonstrated. For solid 3D printing structures, introducing intervals within the solid printing layers—such as using a grid structure instead of a fully solid one, can help to reduce curling and heat effects, thereby improving 3D printing accuracy.

Rheological properties and 3D printability of tomato-starch paste with different types of starch

In this study, the effect of different types of starch (potato, wheat, corn, tapioca, and mung bean) on the quality of three-dimensional (3D) printed food products containing tomato-starch paste (TSP) was investigated. The printability of TSP was evaluated by examining its rheological and textural properties and the microstructure of 3D printed products. The results showed that the tomato starch paste containing wheat starch had the best printing accuracy and print quality compared to the other samples, which had an extruded line width of 0.93 mm and centre heights and diameters of 18.56 mm and 20.15 mm. The macrorheological and microrheological analysis results showed that the apparent viscosity, loss modulus, storage modulus, and viscoelasticity of the TSP containing wheat starch were significantly higher than those of the other samples (P < 0.05). Low-field nuclear magnetic resonance (LF-NMR) results showed that T21 and T22 of TSP containing wheat starch significantly decreased, thereby improving the retention of printed shapes and deposition of 3D-printed TSP. The analysis of textural properties showed that TSP containing wheat starch had significantly higher strength in terms of hardness, elasticity, cohesion and chewiness, which were 9.58 N, 0.58, 0.31 and 2.13 N, respectively (P < 0.05). Thus, the pseudoplastic gel formed by TSP containing wheat starch exhibited a higher fluidity and structural density than the other samples, which improved the extrudability and shape stability of the printed product as well as the self-supporting properties of TSP.

Effect of 3D printing accuracy by wheat starch gel combined with canola oil

This study investigated the impact of canola oil (CO) on wheat starch (WS) in 3D printing, focusing on intermolecular interactions and gel characteristics. 3D printing performance, microstructure, rheology, texture, proton distribution, thermal properties, molecular structures, and crystal structure were used to analyze the properties of starch gels. The results showed that adding CO improved the similarity between printed products and their models, and facilitated smoother extrusion by enhancing the cohesiveness and adhesiveness of the WS-CO complex. Moreover, adding >6 % CO to the starch gels destabilized the 3D-printed structure, causing the top layer to collapse, which affected the aesthetics and printing accuracy. The WS-4%CO complex demonstrated superior printing performance and enhanced accuracy. FTIR (Fourier Transform Infrared) and NMR (Nuclear Magnetic Resonance) results indicated that the interaction between WS and CO involved non-covalent interactions, primarily hydrophobic interactions. SEM (scanning electron microscope) results further revealed the molecular structure, CO hindered the interaction between amylose and amylopectin, disrupting the ordered structure and increasing lamellar formation, thereby affecting the stability of the 3D printing structure. This experiment provides valuable insights for enriching the nutrition and improving the accuracy of 3D-printed food.

Regulation of tapioca starch 3D printability by yeast protein: Rheological, textural evaluation, and machine learning prediction

This article investigated the effects of yeast protein (YP) on gel rheology, texture, and 3D printability of tapioca starch and the feasibility of Principal component analysis (PCA) and support vector machine (SVM) algorithms for classification and prediction of printability. The results indicated that increasing YP content enhanced the viscosity, storage and loss moduli, and hardness, thereby improving extrudability and supportability of 3D printing. The addition of 15% YP exhibited the best 3D printing performance, but excessively high YP addition hindered ink extrusion. PCA analysis based on rheological and texture indices categorized the ink's 3D printing performance into four classes: poor support and low printing accuracy; good support but low printing accuracy; good support and high printing accuracy; and non-smooth extrusion. Furthermore, SVM algorithm used texture data to predict printability classification, with the highest prediction accuracy (91.67%) achieved at polynomial kernel among four different kernel functions. These results confirm that YP can serve as a potential ink for 3D printing and underscore SVM's efficacy in predicting ink's 3D printing performance.

Optically active carbon dot/cellulose nanocrystal hydrogel printing inks with two-step authentication

The counterfeit market in field of consumer goods is still a great obstacle to financial well-being for manufacturers and consumers. Security labels with hidden images have proven to be an effective anticounterfeiting measure. Three-dimensional (3D) printing is an effective approach to fabricating labels with complex geometries using environmentally friendly and cost-effective customized inks. In this work, optically active hydrogels were made by incorporating fluorescent carbon dots (CDs) into a cellulose nanocrystal (CNC) matrix. The CD:CNC ratios were optimized to obtain inks with high viscosity and fidelity that exhibited shear-thinning behavior. The resulting inks showed good printability and the extrusion parameters were optimized to achieve high printing accuracy. When excited at different wavelengths, the printed patterns fluoresced different colors. CNC also showed shear-induced alignment upon extrusion, which is visible under polarized light, allowing hidden images to be incorporated into the printed structures for two-factor authentication.

Development of 3D printed zanthoxylum oil waxy rice cake

As an attractive choice for patients with celiac disease, scaling up production and innovating flavors are significant challenges for the development of traditional Sichuan snack, waxy rice cake. 3D food printing is an emerging technology that enables the production of food with the desired shape and structure. This study introduced two types of Zanthoxylum oil to enhance both the printability and quality of waxy rice cakes, aiming to achieve Sichuan-style taste through the Zanthoxylum oil's effect. The results showed that the waxy rice flour dough with Zanthoxylum oil exhibited shear thinning properties, with viscosity decreasing from 292.59 Pa·s to 91.16 Pa·s at a shear rate of 1 s⁻1, making it an ideal material for 3D printing. The addition of Zanthoxylum oil significantly enhanced water activity and hydrogen bonds in the dough system. Furthermore, the incorporation of red Zanthoxylum oil accelerated the dough maturation process. 3D printing and TPA results revealed that sticky rice cakes containing 8% and 12% Zanthoxylum oil exhibited optimal printing accuracy, with the 8% sample achieving 96.69% fidelity. After steaming, the waxy rice cake with 8% Zanthoxylum oil retained a height of 18.23 mm and a diameter of 31.74 mm, with a soft, sticky texture. In summary, the product with the addition of 8% red Zanthoxylum oil exhibited superior appearance and texture, making it suitable for 3D printing. This study is expected to realize the customized production of Sichuan-style waxy rice cake.

Direct Printing of Disperse Dye Inks to Polyester Fabrics without Chemical Pretreatment.

Direct inkjet digital printing is a relatively green and environmentally friendly textile printing method with a wide range of applications in the textile printing and dyeing industry. However, pretreatment of the fabric is required before digital printing, which will generate certain energy consumption and wastewater. In this study, a digital direct inkjet printing method was developed to improve the printing accuracy of poly(ethylene terephthalate) (PET) fabrics without any pretreatment. A kind of direct inkjet printing ink was prepared by the response change in temperature viscosity. The increase in viscosity inhibits ink bleeding on the fabric, thereby improving printing accuracy. A thermosensitive direct inkjet printing disperse dye ink was prepared by adding cetyltrimethylammonium bromide (CTAB) and 3-methylsalicylic acid (3MS) to the ink. By evaluating the changes in the ink particle size, shear viscosity, and temperature viscosity, it was found that this thermosensitive ink has an excellent average particle size and special changes in viscosity with increasing temperature. When this heat-sensitive ink is printed on a polyester fabric, the fabric does not need pretreatment to improve the clarity of printing, and the printed fabric has satisfactory color fastness to friction and washing.

Fractal-fractional model for the receptor in a 3D printing system

A critical hurdle in three-dimensional printing is the low printing accuracy. In particular, the deformation of the printed object on the receptor makes accurate printing impossible due to insufficient solvent evaporation. We address this challenge by establishing a Murray-like receptor to control the morphology of the printed object, which can be used for accurate printing through efficient residual energy absorption and active vibration attenuation. A fractal oscillator is established and He’s frequency formulation is used to reveal the fractal response of the Murray-like receptor, and an experiment was carried out to show that the receptor system can keep the printed object in good shape without any deformation.

Direct Writing of SiC-polymer nanocomposites for humidity sensing with enhanced performance

Humidity sensors are essential for monitoring humidity levels in various fields. This paper investigates the development and optimization of humidity sensitive SiC-Fe3O4 polymer nanocomposites with varying Fe3O4 concentrations fabricated using Direct Writing (DW) process. The inks were evaluated for flow behavior to ensure proper extrudability through the nozzle. The rheological behavior was then correlated with the printing parameters to optimize the printing accuracy of the nanocomposites. It was observed that all the inks exhibited shear-thinning behavior, enabling a smooth extrusion process. To ensure high-resolution features, a new image analysis method was introduced to quantify corner rounding in printed features, enabling the optimization of printing parameters. In terms of humidity sensing performance, all the inks displayed a change in electrical properties with humidity adsorption. The fabricated nanocomposites showed a decrease in electrical conductivity with increasing humidity, suggesting potential for humidity-sensing applications. Notably, the humidity sensitivity of the nanocomposites was highly dependent on the Fe3O4 concentration in the inks. These findings provide valuable insights into the DW of SiC-Fe3O4 polymer nanocomposites for humidity sensing applications.

Effect of twin-screw extrusion pretreatment on starch structure, rheological properties and 3D printing accuracy of whole potato flour and its application in dysphagia diets

Twin-screw extrusion pretreatment has great potential for the development of three-dimensional (3D) printed food as dysphagia diets. This study aimed to investigate the effect of twin-screw extrusion pretreatment on starch structure, rheological properties and 3D printing accuracy of whole potato flour and its application in dysphagia diets. The results indicated that twin-screw extrusion pretreatment was found to change chain length distributions, short-range ordered structure and relative crystallinity of whole potato flour (WPF), thereby improving its 3D printing performance. With the increasing proportion of long linear chains (DP > 12), the intensity of hydrogen bonds, linear viscoelastic region, storage modulus (G′), loss modulus (G″), viscosity and n of whole potato flour paste were increased, enhancing high printing accuracy and shape retention of 3D printed samples with a denser microstructure and smaller pore diameter distribution. The whole potato flour paste extruded with a peristaltic pump speed at 5.25 mL/min (WPF-4) displayed the highest printing accuracy with excellent rheological properties, good water distribution state and dense network structure, which classified as class 5 level dysphagia diets. This research provides an effective guidance for the modification of whole potato flour using twin-screw extrusion pretreatment as 3D printed food inks for dysphagia patients.

Photocurable Foam for Three-Dimensional-Printed Porous Structures.

In this research, a foam three-dimensional (3D) printing method using digital light processing (DLP) technology was developed to fabricate 3D-printed porous structures. To address the challenges in preparing DLP precursor foam fluid, we designed a specialized foaming device. This device enables the precursor solution to be blended with air, resulting in a stable foam precursor with an adjustable air/liquid fraction and suitable fluidity, crucially enhancing the gas-liquid contact time for the printing process. By manipulation of fluid flow rates, cycle counts, and gas/liquid ratios, one can easily prepare uniform foams with precise control over the pore size and porosity. To avoid significant volume reduction during ultraviolet (UV) curing, nanoparticle fillers were introduced into the network to prevent collapse of the foam structure. Furthermore, the inclusion of an UV absorber enhanced the quality of the printing process by addressing the limitations associated with particle scattering and reflection. The DLP process can readily fabricate intricate structures, featuring a planar resolution below 30 μm and a printing accuracy of less than 1%. Several examples were also demonstrated to highlight the advantages of this technology and its ability to directly print custom foam structures, thereby saving time and material resources.

Sustained release of 3D printed bupropion hydrochloride tablets bearing Braille imprints for the visually impaired

3D printing has been introduced as a novel approach for the design of personalized dosage forms and support patient groups with special needs that require additional assistance for enhanced medication adherence. In this study liquid crystal display (LCD) is introduced for the development of sustained release bupropion.HCl printed tablets. The optimization of printing hydrogel inks was combined with the display of Braille patterns on the tablet surface for blind or visually impaired patients. Due to the high printing accuracy, the Braille patterns could be verified by blind patients and provide the required information. Further characterization revealed the presence of BUP in amorphous state within the photopolymerized resins. The selection of poly(ethylene glycol) (PEG)-diacrylate (PEGDA) of different molecular weights and the presence of surfactants or solubilizers disrupted the resin photopolymerization, thus controlling the BUP dissolution rates. A small batch scale-up study demonstrated the capacity of LCD to print rapidly a notable number of tablets within 24 min.

Rheological characterization and print quality studies of gelatin/collagen I/PEGDA hydrogels

Bioprinting is an up-and-coming technology that uses the basis of additive manufacturing and applies it to the field of tissue engineering. Bioprinting is used to create 3D models of diseased tissue and organs, test cellular responses to drug therapies, and create potentially transplantable organs and vasculature. Bioprinting has gained increasing interest especially in drug discovery, as the traditional 2D cell culture models have been shown to produce results that are not mimicked in animal and human trials. Bioprinters use materials called bioinks, developed from hydrogels which can contain cells and biological factors. While there are commonly used bioinks, there is a need for the development of a diverse range of bioinks for varying applications. In this study, an alternative bioink was developed. The formulations included gelatin, collagen I, and varying amounts of poly (ethylene glycol) diacrylate (PEGDA). These formulations were subject to rheological characterization and print quality analysis. Formulations with higher concentrations of PEGDA had higher degrees of shear-thinning, higher viscosity recovery, lower viscosities, and less dominant gel behavior. The print quality studies showed that the formulations with lower concentrations of PEGDA had better printability, print accuracy, and print fidelity. Formulation P5 had the best overall print quality.

Improvement of 3D printing and subsequent microwave freeze-drying solidification accuracy of pineapple gel-based inks: Infill percentage control and internal models design

The purpose of this study was to improve the 3D printing accuracy of pineapple gel and its subsequent microwave freeze drying (MFD) solidification precision based on infill percentage control (30%, 50%, 70%, and 90%) and internal models design (Hilbert curve, honeycomb, and rectilinear). Through comparing the designed models with the physical dimensions of the printed and dehydrated products, the optimal regulation strategy was obtained. Results showed that the printing deviation of samples decreased initially and then increased with higher infill percentages, with the 70% infill percentage having the lowest deviation. Among all internal models, the rectilinear infill pattern showed the best printing accuracy. Porosity and the shape deformation rate of MFD solidification products initially decreased and then increased with higher infill percentages. The 70% infill percentage products had the lowest shape deformation rate. The honeycomb infill pattern performed best in reducing solidification sample shrinkage and deformation. Additionally, micro-CT scans revealed that the honeycomb infill pattern helped maintain the integrity of each layer's lines of MFD solidification products, closely matching the model's line distribution. In the 50% and 70% infill percentage, honeycomb and rectilinear samples exhibited better crispness. A 70% honeycomb infill pattern was recommended for optimal printing and post-solidification accuracy.

INVESTIGATION ON DIMENSIONAL ACCURACY OF ADDITIVE MANUFACTURED SAMPLES

Fused deposition modelling (FDM) is a typical 3D printing process. Some benefits of FDM-printed components are durability, mechanical property stability, and the quality of the parts. However, it has several drawbacks, such as the emergence of seamlines between layers and the creation of extra material residue on the surface of the printed object, which compromises the dimensional accuracy of the printed part. When making pieces that fit correctly, the dimensions of 3D-printed components must be accurate. This article discusses the dimensional accuracy of 3D-printed components created using an open-source FDM 3D printer. The filament material for printing the test samples is stainless steel, ABS and tough PLA. The test samples were printed three times each and examined using a coordinate measuring machine (CMM). The geometries measured and compared between the three printed sample materials are the thickness, corner radius, angle, perpendicular, hole diameter, and flatness. The result shows that the printed samples could not achieve 100% dimensional accuracy, with stainless steel having the highest accuracy ranging from 99 - 98%. The data of stainless steel were then compared side by side with Tough PLA and ABS, where the accuracy of stainless steel is similar to ABS while PLA has the lowest accuracy. The accuracy of the stainless-steel specimen was then analysed and compared to tough PLA and ABS to identify the printing accuracy of the stainless-steel specimen, which is relatively new.

Printing resolution effect on mechanical properties of porous boehmite direct ink 3D printed structures

Direct ink writing (DIW) is one of the facile and versatile manufacturing techniques for additive manufacturing of ceramics. 3D printed porous boehmite structures fabricated via DIW can offer significant benefits in terms of their high specific surface area and robust mechanical properties, rendering them suitable for applications like catalysis, adsorption, etc. The characteristics of the boehmite structures produced through 3D printing are significantly influenced by several parameters associated with the DIW process, including but not limited to solids concentration in the ink, resolution, and drying time. In this work, for the first time, we try to optimize the DIW parameters for 3D printing of porous boehmite structures to achieve better shape stability, resolution, and mechanical properties. A shear-thinning boehmite ink was prepared by peptization of boehmite powder in nitric acid and the rheological properties were optimized by varying concentrations of boehmite and nitric acid. Boehmite ink with a solid loading of 37 % and a pH of 4 was found to have the optimal rheological properties and printability. A Menger sponge porous structure was printed by DIW using the optimized ink with different sample sizes and resolutions. The resolution and size were optimized for better shape accuracy of printing and structural integrity. Crack-free boehmite structures were obtained by optimizing the drying time. Boehmite structures printed with higher resolution resulted in enhanced compressive strength and energy absorption, i.e., compressive strength and energy absorption of 0.5 mm resolution boehmite structure is enhanced by 208 % and 144 %, respectively, compared to the 1 mm resolution structure.

3D-Printed Melatonin Tablets with Braille Motifs for the Visually Impaired.

An innovative approach for creating customized dosage forms and supporting patient populations with specific requirements who need additional support to improve drug adherence is 3D printing. This work introduces liquid crystal display (LCD) 3D printing as a means of developing melatonin (MLT) tablets. For patients who are blind or visually challenged, Braille patterns were displayed on the tablet surface in addition to the optimization of printing hydrogel inks. Owing to the great printing accuracy, blind patients could validate the Braille patterns that provided the required information. Upon further examination MLT was found to be present in the photopolymerized resins in an amorphous state. The choice of poly(ethylene glycol)-diacrylate (PEGDA) with varying molecular weights and the inclusion of surfactants or solubilizers interfered with the photopolymerization of the resin, hence controlling the rates of MLT dissolution towards the sought sustained release. Nuclear magnetic resonance (NMR) analysis showed that photopolymerization of the PEGDA resins in the printed dosage forms has taken place. A small batch scale-up investigation showed that LCDs could print a significant number of tablets quickly-about twenty-four minutes.

Hofmeister Ions‐Induced Thinning of Gelatin to Enhance 3D Printing Precision

AbstractHydrogel 3D printing holds immense potential in fields like personalized medicine, regenerative therapies, and organ creation, offering biocompatible structures similar to the extracellular matrix. Gelatin‐Methacryloyl (GelMA) emerges as a promising candidate, while its high viscosity poses a significant challenge, especially in vat photopolymerization‐based 3D printing. Here, a new approach is presented by using Hofmeister ionic effect to substantially reduce the viscosity of high‐content (up to 60%) Gelatin bioink at room temperature with enhanced mechanical performance of the printed structures. The thinning effect induced by chaotropic Hofmeister ions is investigated through complex viscosity analysis, optical rotation measurements, and sol–gel conversion studies. The thinning effect induced by chaotropic ions enables precise 3D printing of Gelatin hydrogel, achieving accuracy comparable to prints made with polymers. Furthermore, after polymerization, the cations of the chaotropic salt change their role to cross‐linkers, leading to stronger scaffolds that exhibit biocompatibility with robust cell attachment, proliferation, and suitability for cell growth. The combination facilitates the creation of customizable structures and high printing accuracy will promote the wide application of Gelatin in the development of patient‐specific implants, drug delivery systems, and tissue scaffolds, further improving medical treatment efficacy and personalized healthcare.

3D Printer Nozzle Structure Form Optimal Structural Analysis

The most representative technology of 3D printing is fused deposition modeling (FDM). To improve the printing accuracy of FDM technology, this paper first takes the outlet diameter, angle of convergence, and rectifier section length of the nozzle as the influencing factors. It takes the melt outlet speed stability, viscosity, and outlet pressure as the indexes to design the orthogonal test. Then, COMSOL Multiphysics fluid–solid coupling simulation was used to simulate and analyze the structural characteristics of the 3D printer nozzle, and the range analysis method was used to analyze the data. Finally, the two-phase flow combination was used to simulate the morphological characteristics of the melt flowing out of the nozzle. The results show that the simulation results of the two materials are similar. As the nozzle diameter decreases, the melt pressure decreases, the velocity increases, and the viscosity decreases. For PLA wire rods, the optimal structure of the nozzle is that the outlet diameter is 0.2 mm, the rectifier section length is 1.5 mm, and the angle of convergence is 60°. For ABS wire, the optimum structure of the nozzle is that the outlet diameter is 0.2 mm, the rectifier section length is 1.5 mm, and the angle of convergence is 30°. The nozzle outlet diameter is inversely proportional to the printing accuracy for ABS and PLA materials. The research results provide a theoretical reference for optimizing the nozzle structure for 3D printing.

High-precision and Large-Scale Vat Photopolymerization Printing based on "Spatial-Pixel Integration Compensation" method

Vat photopolymerization (VPP) is widely known for its exceptional printing accuracy, but effectively controlling stitching errors to achieve high-precision, large-scale printing remains a significant challenge. This study introduces a novel compensation method, termed "Spatial-Pixel Integration Compensation" (SPIC), to address this key obstacle. SPIC combines Spatial Motion Compensation to initially control stitching errors between adjacent sub-images to be within 100 µm and Pixel Compensation for precise adjustments, further reducing stitching errors. Integrating SPIC with our high-precision printing system resulted in a remarkable reduction of stitching errors by a factor exceeding 40. Crucially, this method minimizes the stitching error between any two sub-images to be less than one pixel point, specifically below 4 µm. Notably, SPIC is the first method specifically focused on effectively controlling and reducing stitching errors to achieve large-scale printing while maintaining high precision. To validate the practical applicability of the SPIC method, we used SPIC to print both Zig-Zag and herringbone structures (HBS) and achieved high-precision large-scale manufacturing with dimensions of 44 mm × 33 mm. In the HBS structure, the minimum feature size was 14.2 µm, and the printing error was less than 1 µm. These printed structures were used as molds to fabricate proof-of-concept polydimethylsiloxane (PDMS) microfluidic chips, demonstrating the successful mixing of rhodamine B and ethanol within the microfluidic channels. Furthermore, SPIC was extended to the printing of complex three-dimensional (3D) Triple-Periodic Minimal Surface (TPMS) structures, successfully producing TPMS-Gyroid and TPMS-Diamond structures with a minimum feature size of 20 µm and a printing error below 1.5 µm. These results demonstrate that the SPIC algorithm effectively enables high-precision, large-scale printing. This work significantly advances the application of VPP technology in fields requiring complex, high-precision, and large-scale 3D structures and provides valuable insights for future research in high-precision and large-scale printing.