Multidimensional printer
Inventors
Kolmakov, Andrei A. • Holland, Glenn Emerson • Gupta, Tanya
Assignees
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Publication Number
US-11738312-B2
Publication Date
2023-08-29
Expiration Date
2040-07-31
Abstract
A multidimensional printer makes a multidimensional structure from a liquid composition and includes: an energetic crosslinking particle source; a vacuum chamber that receives energetic crosslinking particles from the energetic crosslinking particle source; a membrane that transmits the energetic crosslinking particles; and a sample chamber that: receives a liquid composition that includes a solvent and polymers, the polymers including a cross-linkable moiety subjected to the energetic crosslinking particles such that portions of the polymers proximate to the cross-linkable moieties subjected to the energetic crosslinking particles crosslink to form a solid crosslinked polymer structure, wherein the membrane isolates a vacuum of the vacuum chamber from vapor of the liquid composition in the sample chamber.
Core Innovation
The invention provides a multidimensional printer for making a multidimensional structure from a liquid composition by using energetic crosslinking particles such as electrons or X-rays. The multidimensional printer comprises an energetic crosslinking particle source that produces these particles; a vacuum chamber that receives the energetic crosslinking particles from the source; a membrane that transmits the energetic crosslinking particles while isolating the vacuum of the vacuum chamber from the vapor of the liquid composition in the sample chamber; and a sample chamber that receives the liquid composition containing polymers with cross-linkable moieties. The cross-linkable moieties are subjected to the energetic crosslinking particles to crosslink portions of the polymers and form a solid crosslinked polymer structure.
The problem addressed by the invention is the limitation of conventional additive manufacturing from liquid gels, which are restricted by the diffraction limit of photon optics, limiting spatial resolution to the micron scale. Additionally, conventional techniques like electron beam or X-ray lithography require vacuum conditions and dry samples, limiting three-dimensional printing in continuous processes and preventing patterning in liquid states. The invention overcomes these limitations by enabling crosslinking of polymers in liquid compositions in situ using electrons or X-rays with tunable energy, achieving submicron spatial resolution and enabling two-dimensional and three-dimensional patterning directly in the liquid state.
Claims Coverage
The patent includes one independent claim detailing a multidimensional printer with various components and functionalities, accompanied by dependent claims elaborating specific features and configurations.
Multidimensional printer comprising energetic crosslinking particle source and membrane
A printer for making multidimensional structures from a liquid composition having: an energetic crosslinking particle source producing energetic crosslinking particles; a vacuum chamber receiving and communicating these particles to a membrane; the membrane having a barrier layer and a transmission layer with portions lacking the barrier layer to enable particle transmission; the membrane blocks particles by the barrier layer and transmits particles by the transmission layer; and a sample chamber communicating with the membrane that receives a liquid composition with polymers having cross-linkable moieties, subjects these moieties to the energetic particles to crosslink polymers forming a solid polymer structure, while the membrane isolates the vacuum from vapor of the liquid composition.
Inclusion of a shadow mask to selectively control particle transmission
The multidimensional printer further comprises a shadow mask positioned between the particle source and the membrane, which receives energetic particles and selectively controls their transmission via apertures.
Sample translation stage for spatial control
The printer includes a sample translation stage mechanically coupled to the solid polymer structure within the sample chamber, capable of translating away, toward, or laterally relative to the membrane to spatially control the two- or three-dimensional size or shape of the solid polymer structure during formation.
The claims cover a multidimensional printer capable of producing solid crosslinked polymer structures from liquid compositions by using energetic crosslinking particles transmitted through a specifically designed membrane and controlled via a shadow mask and sample translation stage to achieve spatial and dimensional control over the printed structure.
Stated Advantages
Provides higher spatial resolution than conventional photo-induced three-dimensional printing, achieving submicron lateral and vertical dimensions.
Enables fast printing rates without chemical initiators, overcoming technical deficiencies of conventional methods using crosslink initiators.
Permits micropatterning directly in the liquid state and additive fabrication of multi-compositional two- and three-dimensional gel constructs.
Allows gel encapsulation and patterning of functional entities including live biological objects, composites, and electrodes.
Offers flexible control over resolution, size, and shape through tuning parameters such as beam energy, current, and dwell time.
Allows processing of materials and composites not printable by UV techniques, including those not optically transparent.
Facilitates electron and X-ray lithography in liquid states, enhancing material and device fabrication with unprecedented thickness and dimensional control.
Documented Applications
Fabrication of two-dimensional and three-dimensional hydrogel structures for tissue engineering, soft robotics, biosensing, drug delivery, wound treatment, and biomedical research.
Gel encapsulation of objects such as drugs, biomolecules, and functional nanoparticles.
Gel coating or patterning of live biological objects, composites, and electrochemical electrodes.
In-liquid direct writing and printing of hydrogels with sub-100 nm resolution using electrons or soft X-rays.
Composite hydrogel fabrication including plasmonic microsensors using metal nanoparticles embedded in hydrogels.
Interfacing of live cells with hydrogels for cellular encapsulation and viability testing.
Additive layer-by-layer printing for formation of complex three-dimensional microstructures and patterns.
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