skip to main content
DOE PAGES title logo U.S. Department of Energy
Office of Scientific and Technical Information

Title: One-step volumetric additive manufacturing of complex polymer structures

Abstract

Two limitations of additive manufacturing methods that arise from layer-based fabrication are slow speed and geometric constraints (which include poor surface quality). Both limitations are overcome in the work reported here, introducing a new volumetric additive fabrication paradigm that produces photopolymer structures with complex non-periodic 3D geometries on a timescale of seconds. We implement this approach using holographic patterning of light fields, demonstrate the fabrication of a variety of structures, and study the properties of the light patterns and photosensitive resins required for this fabrication approach. The results indicate that lowabsorbing resins containing ~0.1% photoinitiator, illuminated at modest powers (~10-100 mW) may be successfully used to build full structures in ~1-10 s.

Authors:
ORCiD logo [1]; ORCiD logo [2]; ORCiD logo [3]; ORCiD logo [3]; ORCiD logo [4]; ORCiD logo [4]; ORCiD logo [5]; ORCiD logo [4]
  1. Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States); Massachusetts Inst. of Technology (MIT), Cambridge, MA (United States)
  2. Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States); Univ. of Rochester, NY (United States)
  3. Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States); Univ. of California, Berkeley, CA (United States)
  4. Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)
  5. Massachusetts Inst. of Technology (MIT), Cambridge, MA (United States)
Publication Date:
Research Org.:
Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
1414369
Report Number(s):
LLNL-JRNL-732526
Journal ID: ISSN 2375-2548
Grant/Contract Number:  
AC52-07NA27344
Resource Type:
Accepted Manuscript
Journal Name:
Science Advances
Additional Journal Information:
Journal Volume: 3; Journal Issue: 12; Journal ID: ISSN 2375-2548
Publisher:
AAAS
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; 71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSICS; 37 INORGANIC, ORGANIC, PHYSICAL AND ANALYTICAL CHEMISTRY

Citation Formats

Shusteff, Maxim, Browar, Allison E. M., Kelly, Brett E., Henriksson, Johannes, Weisgraber, Todd H., Panas, Robert M., Fang, Nicholas X., and Spadaccini, Christopher M. One-step volumetric additive manufacturing of complex polymer structures. United States: N. p., 2017. Web. doi:10.1126/sciadv.aao5496.
Shusteff, Maxim, Browar, Allison E. M., Kelly, Brett E., Henriksson, Johannes, Weisgraber, Todd H., Panas, Robert M., Fang, Nicholas X., & Spadaccini, Christopher M. One-step volumetric additive manufacturing of complex polymer structures. United States. doi:10.1126/sciadv.aao5496.
Shusteff, Maxim, Browar, Allison E. M., Kelly, Brett E., Henriksson, Johannes, Weisgraber, Todd H., Panas, Robert M., Fang, Nicholas X., and Spadaccini, Christopher M. Fri . "One-step volumetric additive manufacturing of complex polymer structures". United States. doi:10.1126/sciadv.aao5496. https://www.osti.gov/servlets/purl/1414369.
@article{osti_1414369,
title = {One-step volumetric additive manufacturing of complex polymer structures},
author = {Shusteff, Maxim and Browar, Allison E. M. and Kelly, Brett E. and Henriksson, Johannes and Weisgraber, Todd H. and Panas, Robert M. and Fang, Nicholas X. and Spadaccini, Christopher M.},
abstractNote = {Two limitations of additive manufacturing methods that arise from layer-based fabrication are slow speed and geometric constraints (which include poor surface quality). Both limitations are overcome in the work reported here, introducing a new volumetric additive fabrication paradigm that produces photopolymer structures with complex non-periodic 3D geometries on a timescale of seconds. We implement this approach using holographic patterning of light fields, demonstrate the fabrication of a variety of structures, and study the properties of the light patterns and photosensitive resins required for this fabrication approach. The results indicate that lowabsorbing resins containing ~0.1% photoinitiator, illuminated at modest powers (~10-100 mW) may be successfully used to build full structures in ~1-10 s.},
doi = {10.1126/sciadv.aao5496},
journal = {Science Advances},
number = 12,
volume = 3,
place = {United States},
year = {2017},
month = {12}
}

Journal Article:
Free Publicly Available Full Text
Publisher's Version of Record

Citation Metrics:
Cited by: 16 works
Citation information provided by
Web of Science

Save / Share:

Works referenced in this record:

Diode-based additive manufacturing of metals using an optically-addressable light valve
journal, January 2017

  • Matthews, Manyalibo J.; Guss, Gabe; Drachenberg, Derrek R.
  • Optics Express, Vol. 25, Issue 10
  • DOI: 10.1364/OE.25.011788

Photonic-crystal waveguide structure by pattern-integrated interference lithography
journal, January 2015

  • Leibovici, Matthieu C. R.; Gaylord, Thomas K.
  • Optics Letters, Vol. 40, Issue 12
  • DOI: 10.1364/OL.40.002806

Theory of Molecular Size Distribution and Gel Formation in Branched‐Chain Polymers
journal, February 1943

  • Stockmayer, Walter H.
  • The Journal of Chemical Physics, Vol. 11, Issue 2
  • DOI: 10.1063/1.1723803

Optical trapping and binding
journal, January 2013


Molecular Size Distribution in Three Dimensional Polymers. I. Gelation 1
journal, November 1941

  • Flory, Paul J.
  • Journal of the American Chemical Society, Vol. 63, Issue 11
  • DOI: 10.1021/ja01856a061

Two-photon direct laser writing of ultracompact multi-lens objectives
journal, June 2016


Direct metal writing: Controlling the rheology through microstructure
journal, February 2017

  • Chen, Wen; Thornley, Luke; Coe, Hannah G.
  • Applied Physics Letters, Vol. 110, Issue 9
  • DOI: 10.1063/1.4977555

Strategies to Reduce Oxygen Inhibition in Photoinduced Polymerization
journal, September 2013

  • Ligon, Samuel Clark; Husár, Branislav; Wutzel, Harald
  • Chemical Reviews, Vol. 114, Issue 1
  • DOI: 10.1021/cr3005197

Polymerization Kinetics in Three-Dimensional Direct Laser Writing
journal, August 2014

  • Mueller, Jonathan B.; Fischer, Joachim; Mayer, Frederik
  • Advanced Materials, Vol. 26, Issue 38
  • DOI: 10.1002/adma.201402366

Development of a 3D printer using scanning projection stereolithography
journal, April 2015

  • Lee, Michael P.; Cooper, Geoffrey J. T.; Hinkley, Trevor
  • Scientific Reports, Vol. 5, Issue 1
  • DOI: 10.1038/srep09875

Custom-modified three-dimensional periodic microstructures by pattern-integrated interference lithography
journal, January 2014

  • Leibovici, Matthieu C. R.; Gaylord, Thomas K.
  • Journal of the Optical Society of America A, Vol. 31, Issue 7
  • DOI: 10.1364/JOSAA.31.001515

Holography using pixelated spatial light modulators—part 1: theory and basic considerations
journal, September 2015

  • Haist, Tobias; Osten, Wolfgang
  • Journal of Micro/Nanolithography, MEMS, and MOEMS, Vol. 14, Issue 4
  • DOI: 10.1117/1.JMM.14.4.041310

Ultralight, ultrastiff mechanical metamaterials
journal, June 2014


Three-dimensional light modulation using phase-only spatial light modulator
journal, February 2009


Liquid crystal over silicon device characteristics for holographic projection of high-definition television images
journal, January 2008

  • Georgiou, A.; Christmas, J.; Moore, J.
  • Applied Optics, Vol. 47, Issue 26
  • DOI: 10.1364/AO.47.004793

Multiscale metallic metamaterials
journal, July 2016

  • Zheng, Xiaoyu; Smith, William; Jackson, Julie
  • Nature Materials, Vol. 15, Issue 10
  • DOI: 10.1038/nmat4694

Optical microlithography on oblique and multiplane surfaces using diffractive phase masks
journal, April 2015

  • Wang, Peng; Menon, Rajesh
  • Journal of Micro/Nanolithography, MEMS, and MOEMS, Vol. 14, Issue 2
  • DOI: 10.1117/1.JMM.14.2.023507

Direct-Write Assembly of Three-Dimensional Photonic Crystals: Conversion of Polymer Scaffolds to Silicon Hollow-Woodpile Structures
journal, February 2006

  • Gratson, G. M.; García-Santamaría, F.; Lousse, V.
  • Advanced Materials, Vol. 18, Issue 4
  • DOI: 10.1002/adma.200501447

Impact of Oxygen on Photopolymerization Kinetics and Polymer Structure
journal, April 2006

  • O'Brien, Allison K.; Bowman, Christopher N.
  • Macromolecules, Vol. 39, Issue 7
  • DOI: 10.1021/ma051863l

Sol-Gel Inks for Direct-Write Assembly of Functional Oxides
journal, November 2007

  • Duoss, E. B.; Twardowski, M.; Lewis, J. A.
  • Advanced Materials, Vol. 19, Issue 21
  • DOI: 10.1002/adma.200701372

A versatile diffractive maskless lithography for single-shot and serial microfabrication
journal, January 2010

  • Jenness, Nathan J.; Hill, Ryan T.; Hucknall, Angus
  • Optics Express, Vol. 18, Issue 11
  • DOI: 10.1364/OE.18.011754

Design and optimization of a light-emitting diode projection micro-stereolithography three-dimensional manufacturing system
journal, December 2012

  • Zheng, Xiaoyu; Deotte, Joshua; Alonso, Matthew P.
  • Review of Scientific Instruments, Vol. 83, Issue 12
  • DOI: 10.1063/1.4769050

Two-photon polymerisation for three-dimensional micro-fabrication
journal, July 2006


Experimental demonstration of holographic three-dimensional light shaping using a Gerchberg–Saxton algorithm
journal, January 2005


Design and characteristics of holographic neural photo-stimulation systems
journal, October 2009


Optimized holographic optical traps
journal, January 2005


Multiprocess 3D printing for increasing component functionality
journal, September 2016


Continuous liquid interface production of 3D objects
journal, March 2015


Modeling of Oxygen-Inhibited Free Radical Photopolymerization in a PDMS Microfluidic Device
journal, November 2008

  • Dendukuri, Dhananjay; Panda, Priyadarshi; Haghgooie, Ramin
  • Macromolecules, Vol. 41, Issue 22
  • DOI: 10.1021/ma801219w

Review of selective laser melting: Materials and applications
journal, December 2015

  • Yap, C. Y.; Chua, C. K.; Dong, Z. L.
  • Applied Physics Reviews, Vol. 2, Issue 4
  • DOI: 10.1063/1.4935926

Holographic patterning of high-performance on-chip 3D lithium-ion microbatteries
journal, May 2015

  • Ning, Hailong; Pikul, James H.; Zhang, Runyu
  • Proceedings of the National Academy of Sciences, Vol. 112, Issue 21
  • DOI: 10.1073/pnas.1423889112

A review on stereolithography and its applications in biomedical engineering
journal, August 2010


Reaction behaviour and kinetic constants for photopolymerizations of multi(meth)acrylate monomers
journal, July 1994


Direct Ink Writing of 3D Functional Materials
journal, November 2006


Development of a comprehensive free radical photopolymerization model incorporating heat and mass transfer effects in thick films
journal, March 2002


Three-Dimensional Printing of Elastomeric, Cellular Architectures with Negative Stiffness
journal, May 2014

  • Duoss, Eric B.; Weisgraber, Todd H.; Hearon, Keith
  • Advanced Functional Materials, Vol. 24, Issue 31
  • DOI: 10.1002/adfm.201400451

Spatially addressable design of gradient index structures through spatial light modulator based holographic lithography
journal, December 2013

  • Ohlinger, Kris; Lutkenhaus, Jeff; Arigong, Bayaner
  • Journal of Applied Physics, Vol. 114, Issue 21
  • DOI: 10.1063/1.4837635

Simple and Versatile 3D Printed Microfluidics Using Fused Filament Fabrication
journal, April 2016


Kinetic approach of oxygen inhibition in ultraviolet- and laser-induced polymerizations
journal, November 1985

  • Decker, Christian; Jenkins, Aubrey D.
  • Macromolecules, Vol. 18, Issue 6
  • DOI: 10.1021/ma00148a034

    Works referencing / citing this record:

    High-resolution tomographic volumetric additive manufacturing
    journal, February 2020


    Engineering crack tortuosity in printed polymer–polymer composites through ordered pores
    journal, January 2020

    • Gockowski, Luke F.; Dolinski, Neil D.; Chavez, Roberto
    • Materials Horizons
    • DOI: 10.1039/d0mh00331j