"One Every 60 Seconds"... UNIST Achieves Ultra-Fast Micro 3D Printing [Reading Science]

A domestic research team has developed an ultra-fast 3D printing technology capable of producing three-dimensional microstructures every 60 seconds. This advancement is seen as opening the door to the high-volume on-demand production of customized parts by surpassing the speed limitations of conventional layer-by-layer additive manufacturing methods.

On April 29, Ulsan National Institute of Science and Technology (UNIST) announced that the research team led by Professor Jeong Imdu from the Department of Mechanical Engineering has developed "Dispensing Volumetric Additive Manufacturing (DVAM)" technology, which enables the fabrication of structures inside droplets in a single step. The research results were published online on March 21 in the international journal Advanced Functional Materials, specializing in materials science.

Integrated schematic of high-speed sequential printing technology for droplet rotating volumetric additive manufacturing. a. Volumetric printing principle selectively curing only specific internal positions by irradiating light at multiple angles on a rotating liquid droplet. b. Device configuration that forms and rotates droplets using a syringe and pipette while observing shapes with a camera. c. Continuous manufacturing process where structures are formed inside the droplet, the completed structure is ejected, and the next droplet follows. Provided by the research team

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Conventional 3D printing builds structures by stacking material one layer at a time, resulting in a significant increase in manufacturing time for more complex designs. In contrast, this new technology applies a volumetric printing method, which cures the entire liquid resin droplet at once by irradiating it with light.

In particular, the research team implemented a structure that simultaneously performs printing and ejection within a single resin droplet suspended at the tip of a glass pipette, without the need for a separate container. Once printing is complete, the structure immediately drops onto the substrate, and a new droplet is supplied right away, enabling continuous production.

With this method, it takes approximately 60 seconds to create a single structure. The research team succeeded in continuously manufacturing 10 different three-dimensional structures, such as an Eiffel Tower and sculptures, within 10 minutes.

The main technical challenge was correcting the refraction of light caused by the curved surface of the droplet. To solve this, the research team combined artificial intelligence (AI) with inverse ray tracing calculations.

Photo of the research team. Professor Jeong Imdu (left) and Researcher Jeon Hongryeong. Courtesy of UNIST

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The deep learning-based object recognition system analyzes the shape of the droplet in real time, while the system calculates the light path and projects a pattern to correct for distortion. This enabled high precision without the need for additional refractive index correction solutions.

Jeon Hongryeong, the first author and researcher, explained, "We confirmed the possibility of continuously producing micro-components of different shapes at a speed more than 100 times faster than conventional methods."

Professor Jeong Imdu stated, "This is a fundamental breakthrough in overcoming the slow speed that has been the greatest weakness of 3D printing," adding, "We are now entering an era where it is possible to manufacture desired shapes on demand, within just a few dozen seconds."

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