Additive manufacturing processes continue to benefit from innovation. This week, a group of researchers from Concordia introduced a method of using holograms to 3D print intricate designs and more. Notably, their holographic 3D printing method is seen by many as a solution to many of the current techniques’ shortfalls. Here’s everything you need to know about holographic 3D printing and why it’s the future of the industry.
The 3D printing sector has seen explosive growth over the last decade across all metrics, including users, tech, material science, and methods. The most popular forms of 3D printing still rely on heat and lasers to mold the material into the desired shape. While this strategy has proven effective, it still leaves much to be desired by users.
Direct Sound Printing (DSP)
In 2022, a method of 3D printing using sound waves was introduced to the market. This strategy leverages sound waves to harden print material into a desired shape. Sound Waves are used to create cavitation which occurs whenever the static pressure drops below vapor pressure in a liquid. This state creates milliseconds of high pressure and heat. This heat is used to harden 3D printed materials quickly.
Holographic Direct Sound Printing (HDSP)
Researchers proposed an upgrade to the current DSP method in a recent article published in the journal Nature Communications called Holographic Direct Sound Printing (HDSP). This new approach utilizes acoustic holograms to improve the process. The hologram uses specially patterned acoustic waves that induce cavitation bubbles at specific locations.
Source – Concordia Holographic 3D Printing
The chemically activated acoustic cavitation bubbles provide real-time on-demand regional polymerization, enabling researchers to print using sound more effectively and with more detail. According to the study, the printing process allows engineers to examine and store cross-sectional images of desired prints, enhancing design capabilities and enabling researchers to improve internal structuring.
HDSP Printer
The HDSP printer is set up in a manner that is reversed to many of its predecessors. Rather than the printing arm moving, a motorized platform moves the material within the stationary holographic image. The system utilizes pre-programmed patterns based on advanced algorithms to navigate the robotic arm around the holographic image, enabling the sonochemical reactions to occur and harden the print.
Holographic 3D Printing Test
The research paper delves into some of the testing methods used to qualify the new additive manufacturing process. Researchers conducted a series of sono-chemiluminescence and high-speed imaging experiments to gauge the capabilities and performance of the HDSP. Specifically, key details were tracked including a detailed account of the polymerization process, tuning effects, robotic movements, and software computations.
Holographic 3D Printing Results
The results of the study are game-changing. For one, the researchers noticed that there was a direct correlation between feed rate and their ability to make alterations to complex prints. As such, the team integrated advanced software algorithms to optimize parameters based on the needs of each print. This maneuver resulted in highly accurate printed structures that could outperform previous designs.
The team went on to research the HDSP’s ability to print across a variety of different materials. They also tested the effects of the holograms on the process under different levels of intensity, design, and placement. Lastly, they examined how different structures, such as porosity and materials, affect the tuning process.
Remote Distance Printing (RDP)
The most important breakthrough of this research revolves around remote printing. The engineers found that they could print objects behind walls and other structures using HDSP. This method of internal printing could enable a future where your car parts are printed in place rather than installed. Even more impressive, the same strategy could be used to print organs or repair internal damage in a non-invasive manner.
Benefits of Holographic 3D Printing
The researchers put forth a compelling case as to why HDSP outperforms DSP across nearly every category. For one, it’s much faster than the original DSP method which was limited to a voxel-by-voxel printing strategy. HDSP enables multiple areas to undergo hardening at the same time. The results are that you can print up to 20x faster using DHSP methods.
Make Alterations
Another benefit that HDSP introduces is the ability to alter images during the printing process. In a traditional method of 3D printing, each layer is applied and hardened, meaning that there’s no way to make alterations if the component is already added. HDSP users can alter the hologram, which automatically changes the printing with minimal effort. As such, there’s less waste as this approach reduces printing errors.
Print Complex Designs Using Holographic 3D Printing
HDSP opens the door for a new level of complexity within the market. This printer can create intricate designs with internals utilizing soundwaves, enabling engineers to develop more effective, lightweight options without sacrificing performance and durability.
Multi-Print
Another game-changing advantage the HDSP offers is the ability to create objects simultaneously. The system allows you to maximize efforts by combining multiple prints during a single session. The system can accommodate different prints at different locations, maximizing printing space and lowering print times.
Holographic 3D Printing Offers Flexibility
The HDSP unit is a versatile device that introduced a new level of flexibility to the market. Users can alter printing materials, create intricate shapes, and print across opaque surfaces using this method. This added flexibility will result in further innovation and collaboration across industries.
Impossible to Reach Locations
Another great benefit that HDSP brings to the table is its ability to print in nearly impossible-to-reach locations. Imagine parking your car and a repair drone notifying you that they are going to print you a new fan because your old one is broken. Now, rather than popping the hood, a holographic image is being used to print your new fan in location, no installation is required.
Holographic 3D Printing Potential Applications
There are several potential use case applications for HDSP technology, which could provide some much-needed boost in capabilities across markets in the coming years. Here are the top potential use case applications for HDSPs.
Healthcare
The use of HDSP in the medical and biomedical field will help to lower costs, improve patient safety, and expand access to more regions of the world. HDSP systems are capable of printing complex tissue structures, drug delivery vehicles, and even skin grafts. All of these options improve survivability over their predecessors and can be printed internally, eliminating the need for invasive surgeries.
Researchers
Researchers at Concordia’s Department of Mechanical, Industrial, and Aerospace Engineering conducted the research and testing of the HDSP process. Specifically, a professor named Muthukumaran Packirisamy led the team. Funding for the project came from grants sponsored by FQRNT (Fonds de Recherche du Québec, Canada), NSERC Discovery of R.B., and the Concordia Research Chair.
Companies Making Waves in the 3D Printing Sector
The 3D printing market now includes more options, materials, and devices than ever. You can get anything 3D printed today from a small plastic piece to an entire home and everything in between. These advanced printing operations are opening the door for more innovation and pushing the boundaries of the technology.
Nano Dimension Ltd.
Nano Dimension Ltd entered the market in 2022 and has quickly gained a foothold in the electronic 3D printing sector. The company is best known for its DragonFly printers. These tiny devices allow researchers to print custom circuit boards for nanoscale projects.
Nano Dimension Ltd. (NNDM -1.16%)
Nano Dimension Ltd. (NNDM -1.16%)
Notably, the firm recently released its Dragonfly 4 printer, which has improved its performance. Additionally, the company now offers a laser direct metal printing solution. All of these factors make Nano Dimension Ltd a wise addition to anyone’s portfolio who seeks to enter the nanoscale printing market.
Holographic 3D Printing – Printing Behind Your Skin
The idea of having your organs printed or repaired in your body using soundwaves sounds straight out of a futuristic sci-fi thriller. However, this study makes this seemingly impossible task a reality. When combined with the HDSP’s full capabilities and added performance, it’s easy to see that this printer is set to make some waves moving forward.
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