Corner accuracy in direct ink writing with support material

Abstract

3D printing methods which enable control over the position and orientation of embedded particles have promising applications in cell patterning and composite scaffolds. Extrusion-based additive manufacturing techniques such as fused deposition modeling and direct ink writing can experience particle patterning defects at corners which could hinder cell survival at corners and create unintended property gradients. Here, we propose models which predict the behavior of deposited lines at corners for moderate viscosity inks which are impacted by both capillarity and viscous dissipation. Using direct ink writing with acoustophoresis and a Carbopol-based support gel, we write polygons out of dental resin-based composite inks containing a narrow distribution of microparticles at the center of the filament. A Laplace pressure differential between the inner and outer surfaces of the corner drives corner smoothing, wherein the inner radius of the corner increases. Double deposition, or printing on the same area twice, drives corner swelling, wherein excess ink is diverted to the outer edge of the corner. Fast turns at corners produce ringing, wherein vibrations in the stage manifest in oscillations in the print path. Swelling and ringing effects are apparent in the particle distributions at corners immediately after deposition, while smoothing effects are apparent after the printed structure has had time to relax. When the nozzle returns to write a neighboring line, it imposes shear stresses which mitigate inconsistencies in microstructure at corners by erasing defects which appeared during relaxation. Using a support bath instead of layer-by-layer support suppresses microstructural corner defects.