A brand new method of 3D-printing, inspired by how trees grow, is transforming the way polymers are produced with unprecedented speed and efficiency. A team of researchers at the Beckman Institute for Advanced Science and Technology have developed “growth printing”, an innovative technique that eliminates the need for molds and expensive equipment, slashing production time and cost.
“Completely new manufacturing processes are hard to find. Growth printing is entirely new, which is thrilling,” said project lead Sameh Tawfick, professor of mechanical science and engineering at the University of Illinois Urbana.
Unlike conventional 3D printing, building layer by layer, growth printing expands outward the same way tree rings do. The process begins with a pool of dicyclopentadiene (DCPD) resin, heated at a central point. The heat then spreads outward at 1 mm per second, solidifying the material into poly-dicyclopentadiene (p-DCPD). This rate is more than 100 times faster than common desktop 3D printers and 60 times faster than the world’s fastest-growing bamboo species.
“The speed and energy efficiency of the growth-printing process make this process particularly attractive,” said Philippe Geubelle, professor of aerospace engineering. Researchers can control the final shape by lifting, dipping, or rotating the solidifying material, much like blown glass. The team successfully fabricated axisymmetric shapes, such as a pinecone, raspberry, and squash, and even a small kiwi bird with precise, intricate details.
Printing more sophisticated forms like curved objects is still a challenge, but Tawfick plans large-scale applications, such as manufacturing wind turbine blades. Supported by the U.S. Department of Energy, this innovation could revolutionize polymer manufacturing with a combination of nature’s efficiency and cutting-edge technology.
