Roll-to-roll, high-resolution 3D printing of shape-specific particles

Roll-to-roll, high-resolution 3D printing of shape-specific particles

14 March 2024 | Jason M. Kronenfeld, Lukas Rother, Max A. Saccone, Maria T. Dulay & Joseph M. DeSimone
A scalable, high-resolution 3D printing technique for fabricating shape-specific particles is introduced, based on roll-to-roll continuous liquid interface production (r2rCLIP). This method enables rapid, permutability, and high-resolution fabrication of particles with complex geometries from a variety of materials. The technique uses single-digit micron-resolution optics in combination with a continuous roll of film, allowing for the rapid fabrication and harvesting of particles with intricate designs. The r2rCLIP process achieves voxel sizes as small as 2.0 × 2.0 μm² in the print plane and 1.1 ± 0.3 μm unsupported thickness, at speeds of up to 1,000,000 particles per day. The method demonstrates the ability to fabricate both mouldable and non-mouldable shapes, including geometries not achievable with traditional moulding techniques. The technique is demonstrated with examples of hollow cubes, octahedrons, icosahedrons, and dodecahedrons, as well as drug delivery and ceramic particles. The r2rCLIP process is scalable, enabling the production of thousands to millions of particles per day, and is compatible with a wide range of materials and geometries. The method also allows for the integration of additional steps such as coating, filling, and sterilization, and has potential applications in biomedical, analytical, and advanced materials. The technique is particularly beneficial for applications requiring precise control over particle geometry and material properties, such as drug delivery and microelectronics. The r2rCLIP method offers a versatile and efficient approach to particle fabrication, with potential for industrial-scale production of microdevices such as microrobots and cargo delivery systems.A scalable, high-resolution 3D printing technique for fabricating shape-specific particles is introduced, based on roll-to-roll continuous liquid interface production (r2rCLIP). This method enables rapid, permutability, and high-resolution fabrication of particles with complex geometries from a variety of materials. The technique uses single-digit micron-resolution optics in combination with a continuous roll of film, allowing for the rapid fabrication and harvesting of particles with intricate designs. The r2rCLIP process achieves voxel sizes as small as 2.0 × 2.0 μm² in the print plane and 1.1 ± 0.3 μm unsupported thickness, at speeds of up to 1,000,000 particles per day. The method demonstrates the ability to fabricate both mouldable and non-mouldable shapes, including geometries not achievable with traditional moulding techniques. The technique is demonstrated with examples of hollow cubes, octahedrons, icosahedrons, and dodecahedrons, as well as drug delivery and ceramic particles. The r2rCLIP process is scalable, enabling the production of thousands to millions of particles per day, and is compatible with a wide range of materials and geometries. The method also allows for the integration of additional steps such as coating, filling, and sterilization, and has potential applications in biomedical, analytical, and advanced materials. The technique is particularly beneficial for applications requiring precise control over particle geometry and material properties, such as drug delivery and microelectronics. The r2rCLIP method offers a versatile and efficient approach to particle fabrication, with potential for industrial-scale production of microdevices such as microrobots and cargo delivery systems.
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[slides and audio] Roll-to-roll%2C high-resolution 3D printing of shape-specific particles