Emulsion stereolithography and 3d printing of multimaterials and nanoscale material gradients

Abstract

A functionally graded material is formed by pipetting individual micro-or-nano-litter droplets with a variety of materials including multi-nanostructured material (nanowires, carbon nanotubes, enzymes, multi-element and/or multi-color, multi-biomolecules) and UV polymerization of the flat hydrogel meniscus surface formed at the carrier fluid interface. After step-by-step droplet pipetting and subsequent layer-by-layer UV polymerization via a digital mask, the complete fabricated part without supporting layers is taken out of the carrier fluid while the un-cured micro-litter residue is conveniently suctioned out of the carrier fluid.

1 . An additive manufacturing apparatus for building a product, comprising:
 at least one three dimensional image of the product;   a target surface;   a UV curable material;   at least one functional constituent;   a droplet dispenser for depositing droplets containing said hydrogel material and said functional constituent on said target surface;   a reservoir;   a carrier fluid in said reservoir; and   an energy source adapted to deliver said at least one three dimensional image of the product onto said droplets of said hydrogel material and said functional constituent on said target surface in said reservoir for building the product.   
     
     
         2 . The additive manufacturing apparatus for building a product of  claim 1  wherein said droplets of said hydrogel material and said functional constituent contain less than 200 μL of said hydrogel material and said functional constituent. 
     
     
         3 . The additive manufacturing apparatus for building a product of  claim 1  wherein said functional constituent includes biomolecules for building of artificial organs. 
     
     
         4 . The additive manufacturing apparatus for building a product of  claim 1  wherein said functional constituent includes enzymes. 
     
     
         5 . The additive manufacturing apparatus for building a product of  claim 1  wherein said functional constituent includes nanotubes. 
     
     
         6 . The additive manufacturing apparatus for building a product of  claim 1  wherein said functional constituent includes a multi-color constituent. 
     
     
         7 . The additive manufacturing apparatus for building a product of  claim 1  wherein said functional constituent includes a tissue growth constituent. 
     
     
         8 . The additive manufacturing apparatus for building a product of  claim 1  wherein said energy source is a light source. 
     
     
         9 . The additive manufacturing apparatus for building a product of  claim 1  wherein said energy source is an ultra violet light source. 
     
     
         10 . An additive manufacturing apparatus for building a product, comprising:
 three dimensional images of the product;   a target surface;   a UV curable material;   at least one functional constituent;   a droplet dispenser for depositing droplets containing said UV curable material and said functional constituent on said target surface;   a reservoir;   a carrier fluid in said reservoir;   an elevator for moving said target surface in said reservoir; and   an energy source adapted to sequentially deliver said three dimensional images of the product onto said droplets of said hydrogel material and said functional constituent on said target surface for building the product.   
     
     
         11 . The additive manufacturing apparatus for building a product of  claim 1  wherein the product is an artificial organ and wherein said functional constituent includes biomolecules for building the artificial organ. 
     
     
         12 . The additive manufacturing apparatus for building a product of  claim 1  wherein the product is an artificial organ and wherein said functional constituent includes enzymes for building the artificial organ. 
     
     
         13 . The additive manufacturing apparatus for building a product of  claim 1  wherein the product is an electronic circuit and wherein said functional constituent includes nanotubes for building the electronic circuit. 
     
     
         14 . The additive manufacturing apparatus for building a product of  claim 1  wherein the product is a detector and wherein said functional constituent includes multi-color constituents for building the detector. 
     
     
         15 . The additive manufacturing apparatus for building a product of  claim 1  wherein the product is a wound healing product and wherein said functional constituent includes a tissue growth constituents for building the wound healing product. 
     
     
         16 . An additive manufacturing method of building a product, comprising the steps of:
 producing a computer generated 3D image of the product;   slice the 3D image of the product into a series of individual slices;   producing images of said individual slices;   creating droplets of hydrogel material and functional constituents;   delivering said droplets of hydrogel material and functional constituents to a target surface in a reservoir containing carrier fluid;   using a light source to project a light beam containing said images of said individual slices onto said droplets of hydrogel material and functional constituents in said reservoir to build the product.   
     
     
         17 . The additive manufacturing method of  claim 16  wherein said droplets of hydrogel material and functional constituents contain less than ten μL of said hydrogel material and said functional constituents. 
     
     
         18 . The additive manufacturing method of  claim 16  wherein said functional constituents include biomolecules for building of artificial organs. 
     
     
         19 . The additive manufacturing method of  claim 16  wherein said functional constituents include enzymes. 
     
     
         20 . The additive manufacturing method of  claim 16  wherein said functional constituents include nanotubes. 
     
     
         21 . The additive manufacturing method of  claim 16  wherein said functional constituents include a multi-color constituent. 
     
     
         22 . The additive manufacturing method of  claim 16  wherein said functional constituents include a tissue growth constituent.