Illinois researchers create 3DPX, a 3D-printing technique that draws complex structures inside gel
Scientists at the University of Illinois have unveiled a breakthrough 3D-printing method capable of forming structures directly inside a non-Newtonian gel, enabling shapes that traditional layer-based printing cannot achieve. The technique, called 3DPX, allows objects to be “drawn in air”—with the gel acting as both a support medium and an instant stabilizer.A non-Newtonian gel that behaves like a programmable environment
At the core of 3DPX is a specially engineered gel that responds dynamically to movement and pressure. When the print nozzle moves through it, the gel temporarily parts, allowing the printer to trace complex paths freely. As soon as the printing material is injected, the gel immediately solidifies around it, holding the structure in place without any support scaffolding.This enables free-floating geometries that defy the constraints of gravity and layer stacking, opening the door to new classes of material design.
Forms impossible with traditional 3D-printing
Because the gel supports material from every direction, 3DPX can create shapes that cannot be produced through standard additive manufacturing. Designers can print unbroken closed loops, seamless rings, intricate knots and complex spatial braids—structures that collapse or deform under normal printing conditions.These capabilities may allow researchers to fabricate novel mechanical components, microfluidic devices and next-generation biomedical scaffolds.
Up to 30× faster fabrication
One of the most striking advantages of the new process is speed. Objects that normally take more than 50 hours using conventional printing can be fabricated inside the gel in as little as 10 minutes. This acceleration comes from the elimination of support printing, cooling delays and structural reinforcements.The ability to print ultra-thin features—down to 1.5 microns, comparable to spider silk—further expands potential applications in microengineering and soft robotics.
Compatible with ultrasoft silicone and flexible materials
The system works with exceptionally soft silicones that would otherwise be too fragile for standard printers. The gel prevents deformation and sagging, acting like a controllable suspension medium that holds the material in perfect shape as it cures.Such capabilities could unlock new fabrication methods for wearables, stretchable sensors and biomimetic structures inspired by natural tissues.
Challenges remain for broader adoption
Despite its promise, 3DPX faces technical barriers. The method requires complex calibration, and only certain materials demonstrate reliable curing inside the gel. The specialized gel itself is expensive, and scaling the technique to industrial production will require significant engineering effort.Nonetheless, the research demonstrates a powerful new direction for 3D-printing—a shift from building layer by layer to sculpting freely within a controlled medium.
Editorial Team - CoinBotLab
Source: Phys.org
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