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.

README: Roll-to-Roll, High-Resolution 3D Printing of Shape-Specific Particles

https://doi.org/10.1038/s41586-024-07061-4

https://doi.org/10.5061/dryad.59zw3r2fb

Contains the data for the manuscript titled Roll-to-Roll, High-Resolution 3D Printing of Shape-Specific Particles by J. M. Kronenfeld, L. Rother, M. A. Saccone, M. T. Dulay, and J. M. DeSimone*

*Corresponding Author: jmdesimone@stanford.edu

Stanford University, 318 Campus Drive, Stanford, CA 94305-5427

Description of the Files

The following files are included in this online repository in support of the respective manuscript and as required by funding agencies:

Computer Aided Design .stl Files:
- 1_to_1_Jack.stl [1]
  - 1:1 Jack 3D model as printed and shown in Figure 3
- Capped_Hollow_Cone.stl
  - Capped Hollow Cone 3D model as printed and shown in Figure 3
- Cube.stl
  - Cube 3D model as printed and shown in Figure 3
- Dodecahedron.stl
  - Dodecahedron 3D model as printed and shown in Figure 1d and Figure 3
- Drug_Delivery_Cube_Bottom.stl and Drug_Delivery_Cube_Top.stl [2]
  - Components of drug delivery cube 3D model as printed and shown in Figure 3 and Figure 4c-f
- Gyroidal_Cube.stl
  - Gyroidal Cube 3D model as printed and shown in Figure 3
- Hollow_Circle.stl
  - Hollow Circle 3D model as printed and shown in Figure 3
- Hollow_Cube.stl
  - Hollow Cube 3D model as printed and shown in Figure 1c, Figure 3, Figure 4a-b, Extended Data Figure 1b-i, and mass production demonstration
- Hollow_Tetrahedron.stl
  - Hollow Tetrahedron 3D model as printed and shown in Figure 1a-b, Figure 3, and Extended Data Figure 1a
- Icosahedron.stl
  - Icosahedron 3D model as printed and shown in Figure 1d and Figure 3
- L_Shape.stl
  - L-Shape 3D model as printed and shown in Figure 3
- Octahedron.stl
  - Octahedron 3D model as printed and shown in Figure 1d and Figure 3, and mass production demonstration
- Overhang_Clip.stl
  - Overhang Clip 3D model as printed and shown in Figure 3
- Tetrahedral_Jack.stl
  - Tetrahedral Jack 3D model as printed and shown in Figure 3
Working Curve Extended Data:
- Resin_Working_Curve_Data.xlsx
  - Contains all resin working curve data including bridge dosage series, replicate bridge thickness measurements, and respective intensities. Organized by tab for each resin presented in Table A. Each tab contains bridge series Sample ID, bridge number for reference, qualitative notes on bridge, exposure time, exposure intensity, post-filter exposure intensity, greyscaling percentage, window-delivered sample intensity, calculated natural log of intensity, average bridge sample thickness and associated standard error of sample, and respective replicate bridge thickness measurements for each sample. Cells marked with green fill on each sheet indicate the lowest mean bridge thickness measured of each respective data set.
Thermogravimetric Analysis Data:
- TGA_SIL30.txt
  - Raw TGA data corresponding to Extended Data Figure 3a
- TGA_HDDA_Ceramic_Mix.txt
  - Raw TGA data corresponding to Extended Data Figure 3c
X-ray Diffraction Data:
- Dependent variable in units of degrees and independent variable in dimensionless absorbance units, respectively; intensity is recorded in units of counts for .csv files.
- XRD_SIL30_800C.xy
  - Raw XRD data corresponding to Extended Data Figure 3b
- XRD_SIL30_1200C_slowscan.csv
  - Raw XRD data corresponding to Extended Data Figure 3b
- XRD_SIL30_1400C_45minScan.csv
  - Raw XRD data corresponding to Extended Data Figure 3b
- XRD_HDDA_Ceramic_Mix_1400C_x2_6hourSlow.csv
  - Raw XRD data corresponding to Extended Data Figure 3d
Energy-Dispersive X-ray Spectroscopy Data:
- EDS_Ceramic_Cubes_Surface.xlsx
  - Raw EDS data corresponding to Figure 4b

[1] Model adapted from Athanassiadis, A. G. et al. Particle shape effects on the stress response of granular packings. Soft Matter 10, 48–59 (2013).

[2] Model adapted from McHugh, K. J. et al. Fabrication of fillable microparticles and other complex 3D microstructures. Science 357, 1138–1142 (2017).

Additional Information

All source data is provided with the manuscript and is available online via the publisher.

Should any raw data files be needed in another format they are available from the corresponding author upon reasonable request.

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

Data files

Abstract

README: Roll-to-Roll, High-Resolution 3D Printing of Shape-Specific Particles

Description of the Files

Additional Information