3D-Printing Breakthrough Delivers One Resin with Two Functions
In a leap forward for additive manufacturing, researchers have developed a revolutionary 3D-printing method that allows a single resin to create both solid structures and dissolvable supports. The implications? Faster, cleaner, and far more efficient 3D-printing workflows, potentially transforming industries from biomedical engineering to aerospace.
The work, published in ACS Central Science, centres on a clever bit of chemistry that allows a new type of resin to respond differently based on the type of light it’s exposed to. One beam triggers the formation of robust, permanent structures; the other conjures up temporary supports that can be washed away without a trace. The result: a streamlined, single-pot process that reduces time, cuts material waste, and opens doors for designing more intricate geometries.
Tackling the 3D-Printing Bottleneck
Ask any experienced engineer or designer about vat photopolymerization, and you’ll hear plenty about its speed and resolution. But you’ll also hear a common complaint: removing structural supports is a fiddly, time-consuming task. Supports are essential to hold up complex overhangs during printing, but the post-processing stage—removing them without damaging the object—can be a nightmare.
Dr Maxim Shusteff, a corresponding author on the study, explains the problem: “Vat photopolymerization is known for its fast and high-resolution printing, but one of the most nerve-wracking parts after printing is manually removing supports for intricate interlocking and overhang structures. We are very excited that we can use simple chemistry to solve this issue.”
Traditionally, fabricators print the main object in one resin and the supports in another, requiring a resin change mid-process. That adds time, complexity, and expense. But the new method—pioneered by Shusteff, Sijia Huang, and their colleagues—does it all in one go.
Light That Knows Its Job
So, what’s the secret sauce? It lies in the selective use of light. The team developed a novel resin formulation containing acrylate/methacrylate and epoxy monomers, as well as a photoreactive substance sensitive to both visible and UV light.
Under visible light, the acrylate monomers react to form dissolvable anhydride-based supports. Expose the same resin to UV light, and it’s the epoxy monomers that solidify into the object’s permanent structure. And because both reactions occur independently, the printer can build both components—object and support—at the same time.
To remove the supports? Just dunk the printed object into a sodium hydroxide solution at room temperature. Within 15 minutes, the anhydride-based scaffolds melt away, leaving the final object clean and undamaged. Better still, the degradation process is eco-friendly. The supports break down into non-toxic by-products, reducing environmental impact—a win-win for sustainability and efficiency.
Demonstrating the Chemistry in Action
Once the resin proved itself in the lab, it was time for a real-world test. The researchers printed increasingly complex designs to showcase the technique’s versatility. Among the creations: a checkerboard pattern, a cross, a pair of interlocking rings, a ball-in-cage structure, and even two balls spiralling in a helix.
These aren’t just gimmicks. Such structures would’ve been a real headache—if not impossible—with conventional support removal methods. The team’s success underscores the breakthrough’s potential across multiple disciplines, particularly where complex geometries are essential.
Bridging the Gap in Biomedical Engineering
One of the most promising frontiers for this technology lies in biomedicine. Think: tissue engineering scaffolds with complex internal lattices, joints and hinges in prosthetics, or bespoke implants requiring high accuracy and delicate structural balance. In all these applications, minimising post-processing reduces risks, enhances precision, and saves time.
Additionally, the use of non-toxic, degradable support material is a huge plus. In biomedical contexts, avoiding harmful residues is critical. This new resin makes that possible, enabling safer, cleaner components straight off the printer bed.
Printing Without Compromise
The technique also holds strong potential in fields such as robotics, automotive design, consumer electronics, and even high-end architecture. Essentially, anywhere that intricate, support-heavy designs were once hindered by clunky post-processing, this approach offers a way forward.
By printing the object and supports simultaneously, engineers can now design with fewer compromises. Internal voids, suspended structures, interlocking systems—these are all easier to achieve, and far less stressful to manufacture.
Purpose-Built Printer Seals the Deal
Alongside the resin itself, the researchers developed a custom 3D printer capable of emitting both UV and visible light. This dual-wavelength setup allows precise control over which parts of the resin harden into which type of material. It’s not just a chemistry breakthrough; it’s an entire ecosystem built from the ground up.
While commercial versions of such printers aren’t on the market yet, it’s only a matter of time before manufacturers pick up on the potential. Streamlined workflows and fewer material swaps could lead to reduced costs and higher productivity across multiple industries.
Backed by Science, Powered by Innovation
This breakthrough didn’t come out of nowhere. It was made possible by funding from the U.S. Department of Energy, the University of California Laboratory Research Fees In-Residence Graduate Fellowship, and the Lawrence Postdoctoral Fellowship at Lawrence Livermore National Laboratory.
And while the American Chemical Society (ACS) didn’t conduct the research itself, its publication of the work is testament to its mission. With a global reach and a sharp focus on integrity and accessibility, ACS continues to lead the way in disseminating cutting-edge chemical science to a worldwide audience.
Reinventing the Future of 3D Printing
Let’s take a step back. This isn’t just a new trick—it’s a fundamental shift in how we approach design for additive manufacturing. By collapsing what was once a multi-step process into a seamless, one-pot solution, the door’s been thrown open for a wave of innovation.
As researchers continue to refine the chemistry, and as 3D-printer manufacturers catch up with compatible hardware, it’s fair to say we’re entering a new chapter in the world of fabrication. One where form no longer needs to follow the limitations of function.
