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Dryad

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

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Feb 09, 2024 version files 7.59 MB

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Abstract

Particle fabrication has attracted recent attention due to its diverse applications in bioengineering, drug and vaccine delivery, microfluidics, granular systems, self-assembly, microelectronics, and abrasives. Herein we introduce a scalable, high-resolution, 3D printing technique for the fabrication of shape-specific particles based on roll-to-roll continuous liquid interface production (r2rCLIP). We demonstrate r2rCLIP using single-digit, micron-resolution optics in combination with a continuous roll of film (in lieu of a static platform), enabling the rapidly permutable fabrication and harvesting of shape-specific particles from a variety of materials and complex geometries, including geometries not possible to achieve with advanced mould-based techniques. We demonstrate r2rCLIP production of mouldable and non-mouldable shapes with 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. Such microscopic particles with permutable, intricate designs enable direct integration within biomedical, analytical and advanced materials applications.