Influence of Light-Intensity-Dependent Droplet Directionality on Dimensions of Structures Constructed Using an In Situ Light-Guided 3D Printing Method

As an alternative to conventional 3D printing methods that require supports, a new 3D printing strategy that utilizes guided light in situ has been developed for fabricating freestanding overhanging structures without supports. Light intensity has been found to be a crucial factor in modifying the dimensions of structures printed using this method; however, the underlying mechanism has not been clearly identified. Therefore, the light-intensity-dependent changes in the structure dimensions were analyzed in this study to elucidate the associated mechanism. Essentially, the entire process of deposition was monitored by assessing the behavior of photocurable droplets prior to their collision with the structure using imaging analysis tools such as a high-speed camera and MATLAB(®). With increasing light intensity, the instability of the ejected falling droplets increased, and the droplet directionality deteriorated. This increased the dispersion of the droplet midpoints, which caused the average midpoints of the deposited single layers to shift further away from the center of the structure. Consequently, the diameter of the structure formed by successive stacking of single layers increased, and the layer thickness per droplet decreased. These led to light-intensity-dependent differences in the diameter and height of structures that were created from the same number of droplets.