The application space for 3D printing is wide and promising but fraught with trade-offs. Printing large objects means long print times, and large machines. By harnessing a unique two-step foaming resin, we've developed a way to turn an ordinary commercial MSLA printer (under $300) into a large-scale foam fabrication system. Our unique formulation employs a light-activated curing agent, allowing it to be structurally patterned like an ordinary lithographic 3D printing resin, but also contains a heat-activated isotropic foaming agent, allowing it to expand by up to 40x (by volume) when placed in an ordinary oven at 200 °C, allowing for the creation of structures which are significantly larger than the build volume of the 3D printer which produced them. This process is scalable and the chemical feedstocks are all low in cost and commercially available. Complex geometries such as Voronoi structures, functional wind turbines, and floatation aids composed of porous foams are presented along with timelapse videos of their fabrication, expansion and testing. Potential applications for our novel resin include architecture, aerospace, energy, and medical devices.

Expanding the application space for lithographic 3D printing with post-expandable foaming resins

ACS Spring 2022

The official archive and repository for all ACS Meetings & Expositions abstracts and select posters or presentations.