A research team at the Beckman Institute for Advanced Science and Technology has developed a new additive manufacturing process based on the natural way trees grow. Growth printing (GP) makes it possible to produce polymer components efficiently and without conventional molds or expensive equipment. The method was published in the journal Advanced Materials and led by Professor Sameh Tawfick from the University of Illinois Urbana-Champaign.
The method uses a self-propagating polymerization front triggered by an exothermic reaction of dicyclopentadiene (DCPD). As soon as a heated initiator comes into contact with the liquid, uncured resin, the frontal polymerization reaction starts, which propagates isotropically in a radial direction. The continuous upward movement of the initiator pulls the cured component out of the uncured resin. The growth shape of the resulting object is controlled by the movement trajectory of the initiator relative to the free resin surface. This process enables efficient shaping and reduces the need for complex support structures.
“Humans are incredibly talented at making things. Completely new manufacturing processes are hard to find. Growth printing is entirely new, which is thrilling,” said Sameh Tawfick , a professor of mechanical science and engineering at the University of Illinois Urbana-Champaign and project lead.
An inverse design algorithm was developed to simulate solidification using reaction-diffusion models and produce precise components. The process is characterized by high energy efficiency and comparatively fast production times. With a polymerization front propagation speed of 1 mm per second, the process is not faster than existing additive manufacturing methods, but offers significant advantages due to the lower material and energy requirements.
Growth printing could be particularly relevant for applications in the production of resistant polymer components that are to be manufactured without complex post-processing. The combination of energy-efficient curing and controllable growth opens up new possibilities for resource-saving production in additive manufacturing.
Metal Binder Jetting: The Key to Efficient Tool Manufacturing? - Exclusive Insights from INDO-MIM
Fill out the form and get instant access to an exclusive webinar on HP's Metal Binder Jetting 3D printing technology with exciting insights from INDO-MIM.Subscribe to our Newsletter
3DPresso is a weekly newsletter that links to the most exciting global stories from the 3D printing and additive manufacturing industry.
