Researchers at The University of Texas at Austin have developed a new 3D printing method that combines soft and hard materials into a single object using different colors of light. This innovation could lead to advancements in prosthetics, flexible medical devices, and stretchable electronics. The process is detailed in a paper published in Nature Materials.
Zak Page, an assistant professor of chemistry at UT Austin and corresponding author, stated, “What really motivated me and my research group is looking at materials in nature.” He explained that nature blends hard and soft materials seamlessly without failure at the interface. The researchers aimed to replicate this phenomenon.
A related study by Page and others was published on May 29 in ACS Central Science. The journal’s editors commended the work as “the future of 3D printing,” highlighting how light can be used not just for curing resin but as a precise tool for additive manufacturing.
“This approach could make additive manufacturing more competitive for higher-volume production compared with traditional processes like injection molding,” said Keldy Mason, lead author of the ACS Central Science study and a graduate student in Page’s lab. He added that it opens up new design possibilities.
The challenge in creating objects with different physical properties lies in the tendency of materials to fail at their interfaces. To address this, the team designed a liquid resin activated by dual-light printing systems which trigger different chemical reactions based on light color. Violet light cures the resin into a rubber-like material while ultraviolet light makes it rigid.
Page explained, “We built in a molecule with both reactive groups so our two solidification reactions could ‘talk to each other’ at the interface.” This strengthens the connection between soft and hard parts allowing gradual transitions if desired.
The researchers demonstrated their system by printing a functional knee joint with flexible ligaments and rigid bones. They also created a prototype stretchable electronic device with gold wire that can bend without breaking circuits due to its rigid sections.
“Honestly, what surprised me most was how well it worked on the first try,” Page remarked about their success with 3D printing resins. He noted significant differences between properties where soft parts behaved like rubber bands while hard parts were as strong as consumer plastics.
This method operates faster with better resolution than previous techniques and may become accessible to various sectors due to its simplicity and affordability. “It could be used to prototype surgical models, wearable sensors or even soft robots,” Page said about potential applications.
Authors contributing to these studies include Ji-Won Kim among others from UT Austin along with contributors such as Jenna M. Nymick from ACS Central Science paper collaborations supported by organizations like U.S Department Of Defense among others mentioned within acknowledgments provided herein further down below…
The University emphasizes transparency regarding potential conflicts; financial disclosures were submitted accordingly alongside patent filings under #PCT/US2024/035169 concerning technology described above involving contributions notably made hereinabove mentioned collectively throughout entirety thereof…
