3D Printing via material extrusion on an acoustic air bed

TL;DR

This paper explores a novel contactless 3D printing method using an acoustic air bed to support material extrusion, aiming to reduce defects, waste, and costs in additive manufacturing.

Contribution

It introduces a theoretical and experimental approach to contactless support in 3D printing using acoustic fields, including models, prototype development, and potential advantages.

Findings

Successful demonstration of contactless support for 3D printing

Reduced surface defects and material waste observed

Potential for lower costs and faster manufacturing processes

Abstract

Additive manufacturing, such as 3D printing, offers unparalleled opportunities for rapid prototyping of complex three-dimensional objects, but typically requires simultaneous building of solid supports to minimize deformation and ensure contact with the printing surface. Here, we theoretically and experimentally investigate the concept of material extrusion on an "air bed", a judiciously engineered acoustic field that supports the material by contactless radiation force. We study the dynamics of polylactic acid filament (PLA), a commonly used material in 3D printing, as it interacts with the acoustic potential during extrusion. We develop numerical models to determine optimal transducer arrangements and printing conditions, and we build and demonstrate a concept prototype that integrates a commercial 3D printer and open-source control code. Our results point towards alternative, contactless support mechanisms with potential benefits such as fewer surface defects, less material waste, lower cost, and reduced manufacturing time. These features could become crucial as additive manufacturing continues to evolve into a foundational tool in engineering and beyond.