This New Ultrasound-Based 3D Printing Tech Could Pave the Way for Less Invasive Surgeries

A novel breakthrough in three-dimensional (3D) printing is emerging, featuring an innovative technique that utilizes ultrasound waves for crafting objects from sonically cured inks.

This cutting-edge approach, termed deep-penetrating acoustic volumetric printing (DAVP), holds the promise of revolutionizing volumetric 3D printing, even within opaque media and at significant penetration depths, potentially transforming the creation of body implants, according to the research team behind this work.

To keep surgeries less invasive, it would be better if implants could be injected into the body in liquid form and then solidified once in place. And this ultrasound-based 3D printing process can make that possible in the future.

All About Volumetric Printing

The domain of 3D printing stands at the forefront of altering manufacturing processes across diverse applications. Volumetric printing, an emerging technique in 3D printing, showcases the ability to construct objects swiftly and with enhanced surface quality compared to traditional layer-by-layer methods.

The research team noted that traditional volumetric printing relies on light to induce photopolymerization in optically transparent inks. However, challenges such as light scattering, the presence of additives, and hindrances from already cured portions have constrained material choices, especially in configurations demanding deep light penetration.

In a departure from traditional methods, a team led by Xiao Kuang introduced DAVP, a technique utilizing focused ultrasound waves and a specially formulated "sono-ink."

This innovative ink addresses pivotal challenges in acoustic volumetric printing, utilizing a thermally responsive adaptive acoustic absorber to create a viscous gel. This gel prevents streaming flow while initiating heat-triggered polymerization, overcoming obstacles in the process.

In practical tests, DAVP was reported to have demonstrated printing objects from various nanocomposite materials at a millimeter scale, reaching depths of several centimeters even in opaque media.

Potential Applications of DAVP

The potential applications of DAVP extend beyond traditional manufacturing. The researchers applied this technique to high-speed, high-resolution through-tissue manufacturing and explored its utility in minimally invasive medicine.

By conducting experiments in ex vivo tissues infused with sono-ink, the researchers demonstrated the on-site fabrication of artificial bone and the development of closure for the left atrial appendage.

"DAVP achieves the key features of low acoustic streaming, rapid sonothermal polymerization, and large printing depth, enabling the printing of volumetric hydrogels and nanocomposites with various shapes regardless of their optical properties," the study's abstract reads.

"DAVP also allows printing at centimeter depths through biological tissues, paving the way toward minimally invasive medicine," it added. The study, titled "Self-enhancing sono-inks enable deep-penetration acoustic volumetric printing," was published in the journal Science.