Advanced holographic 3D printing with acoustic technology

HDSP, detailed in Nature Communications, builds upon previous work in sonochemical reactions and cavitation, which harness microscopic bubbles to create intense heat and pressure for brief moments. These reactions harden resin into intricate patterns, forming the basis for complex 3D structures. The latest development embeds this technique within acoustic holograms, allowing for rapid polymerisation. Instead of building objects voxel by voxel, this method creates entire structures simultaneously, enhancing speed and efficiency.

To maintain image fidelity, the acoustic hologram is fixed within the printing material, while a robotic arm moves the platform according to a pre-programmed algorithm.

Professor Muthukumaran Packirisamy, who led the project, noted: “We can also change the image while the operation is under way. We can change shapes, combine multiple motions, and alter materials being printed. We can make a complicated structure by controlling the feed rate if we optimise the parameters to get the required structures.” According to Packirisamy, this method could boost printing speeds up to twentyfold while reducing energy consumption.

A leap in 3D printing precision and versatility

The researchers emphasise the unique control HDSP provides over acoustic holograms, which can store multiple images in a single hologram. This capability allows for the simultaneous printing of multiple objects within the same space. This technology could prove especially valuable in fields such as advanced tissue engineering, drug delivery, and medical implants. For instance, the ability to create complex structures from various materials could lead to the development of tissue scaffolds or targeted drug delivery systems, with potential real-world applications including skin grafts and precision therapy.

Moreover, as sound waves can penetrate opaque surfaces, HDSP can print within concealed or internal spaces. This capability could be transformative for sectors requiring intricate repairs, such as internal organ repairs or aircraft component maintenance.

Packirisamy draws a parallel between HDSP’s potential and the evolution of light-based 3D printing, comparing it to the leap from stereolithography, which hardens resin point by point, to digital light processing, which cures whole layers simultaneously. He explains: “You can imagine the possibilities. We can print behind opaque objects, behind a wall, inside a tube, or inside the body. The technique that we already use and the devices that we use have already been approved for medical applications.”