3D With Rays

Using rays to 3D print? Is that even possible?

A new 3D printer uses light to transform gooey liquids into complex solid objects in only a matter of minutes. Nicknamed the “replicator” by the inventors — after the Star Trek device that can materialize any object on demand — the 3D printer can create objects that are smoother, more flexible and more complex than what is possible with traditional 3D printers. It can also encase an already existing object with new materials — for instance, adding a handle to a metal screwdriver shaft — which current printers struggle to do.

The technology has the potential to transform how products from prosthetics to eyeglass lenses are designed and manufactured, the researchers say.

“I think this is a route to being able to mass-customize objects even more, whether they are prosthetics or running shoes,” said Hayden Taylor, assistant professor of mechanical engineering at UC Berkeley and senior author of a paper describing the printer.

“The fact that you could take a metallic component or something from another manufacturing process and add on customizable geometry, I think that may change the way products are designed,” Taylor said.

Most 3D printers, including other light-based techniques, build up 3D objects layer by layer. This leads to a “stair-step” effect along the edges. They also have difficulties creating flexible objects because bendable materials could deform during the printing process, and supports are required to print objects of certain shapes, like arches.