Remote printing method and system

Abstract

According to the invention, a new concept is introduced into additive manufacturing (AM), namely remote printing can be carried out without directly accessing a printing position. Energy sources commonly used in AM, such as heat and light, have weak penetrability in optically opaque media. However, the present invention introduces a method of deep penetration of print media by using acoustic waves. The acoustic mode creates a chemically active region in the printing material, causing the printing material to cure. The printing material may be a thermoset polymer or a polymer composite. According to the concept, a new paradigm for non-invasive / minimally-invasive biological printing in the human body is created, an operation is not needed, and the concept passes experimental verification in the patent. In addition, a new concept of printing under a firm and opaque shell is introduced, the concept has industrial application value and is particularly suitable for the aerospace field, and the generated size is smaller than the size which can be achieved at present.

Description

Cross-reference to related applications

[0001] This patent application claims priority to U.S. Patent Application No. 673 / 500,681, filed on May 8, 2023. Technical Field

[0002] This patent application relates to additive manufacturing, and more specifically, to acoustically triggered ultraactive microreactors (UAMRs) for providing remotely printed structures that can be printed under a robust and opaque shell via acoustically triggered UAMRs, which has industrial application value, especially suitable for aerospace or media such as human / animal tissues. Background Technology

[0003] Additive manufacturing (AM) processes are typically based on curing buildup materials pixel-by-pixel and layer-by-layer to create three-dimensional objects. Volumetric printing techniques have also been introduced recently, creating a three-dimensional image of the desired object within a container filled with printing material. However, despite all the developments in AM technology to date, light and heat remain the primary energy sources for the polymerization reaction or the deposition / melting of the printing material within the AM process. These factors limit the penetration depth of the energy source within the medium of the cured printing material.

[0004] Therefore, the inventors have established a novel printing paradigm called Remote Printing (RDP), in which, for example, a chemical reaction is induced using sound waves, and the curing process of the printing material is driven by using the sonochemical pathway of sound waves. By employing a triggering mechanism compatible with chemical reaction triggering and allowing the signal to propagate in an intermediate medium, the penetration depth of this triggering mechanism (i.e., the energy source) can be flexibly adjusted, and this penetration depth is significantly improved compared to the AM scheme in the prior art.

[0005] Other aspects and features of the invention will become apparent to those skilled in the art from the following description of specific embodiments in conjunction with the accompanying drawings. Summary of the Invention

[0006] The purpose of this invention is to alleviate the limitations of existing additive manufacturing technologies, and more specifically, to provide acoustically triggered ultraactive microreactors (UAMRs) for providing remotely printed structures that can be printed under a robust and opaque shell via acoustically triggered UAMRs, which has industrial application value, especially suitable for aerospace or media such as human / animal tissues.

[0007] According to an embodiment of the present invention, a method for forming a three-dimensional (3D) object is provided, comprising: Provides one or more sound sources configured to generate a pressure field within a printing material, the pressure field including at least one of a focused pressure field and a non-focused pressure field; and The pressure field is moved by shifting at least one of the one or more subsets of sound sources, or by adjusting the phase of the pressure field generated by one or more sound sources; wherein, A pressure field generated by one or more sound sources triggers the formation of highly chemically active regions within the printing material, thereby solidifying a portion of the printing material and forming a 3D object by moving the pressure field.

[0008] According to an embodiment of the present invention, a method for forming a three-dimensional (3D) object is provided, comprising: Provide one or more energy sources, configurable to regions within the printed material to generate trigger chemical regions; and The region is moved by shifting at least one of one or more subsets of sound sources, or by adjusting the phase of the pressure field generated by one or more sound sources; wherein, A region generated by one or more energy sources triggers the formation of a highly chemically active region within the printing material, thereby solidifying a portion of the printing material and forming a 3D object by moving the region.

[0009] Other aspects and features of the invention will become apparent to those skilled in the art from the following description of specific embodiments in conjunction with the accompanying drawings. Brief description of the attached figures

[0010] Embodiments of the invention will now be described by way of example only, with reference to the accompanying drawings, in which: Figure 1A and Figure 1B A comparison is shown between light-based additive manufacturing (AM) and embodiments of the present invention that use sound fields in optically opaque materials; Figure 2A and Figure 2B The diagrams illustrate the concept of Remote Printing (RDP) and a detailed schematic of an Ultra-Active Microreactor (UAMR). Figure 3 Four different optically opaque polymer composite materials printed using an RDP system according to embodiments of the present invention are shown; Figure 4A This illustration shows a sintered opaque printing material formed using an RDP system according to an embodiment of the present invention, the material comprising polydimethylsiloxane (PDMS) loaded with silica / alumina (DMA). SiO 2 / Al2O 3-PDMS), aluminum-loaded PDMS (Al-PDMS), and iron-loaded PDMS (Fe-PDMS). Figure 4B It shows SiO 2 / Al2OX-ray diffraction (XRD) patterns of 3-PDMS, Al-PDMS and Fe-PDMS ceramic components; Figure 4C The crystallization peaks of the Al-PDMS ceramic component are shown. Figure 4D The Fourier transform infrared (FTIR) spectra of the Fe-PDMS composite material after printing (polymer part) and after pyrolysis (ceramic part) are shown. Figure 5 A schematic diagram of RDP for deep in vivo printing is shown; Figure 6A A schematic diagram of the experimental RDP device used by the inventor is shown; Figure 6B An image of a conceptual RDP device for in vitro / ex vivo validation is shown; Figure 6C A cross-sectional view of the human skin and muscle tissue phantom used in the prototype experiment is shown. Figure 6D It shows the use of Figure 6C Images of tissue model printed parts; Figure 7A The image shows pig tissue, including skin, fat, and muscle, used in the prototype experiment. Figure 7B It shows the use of Figure 7A Images of printed parts of pig tissue; Figure 8A and Figure 8B The 3D models and printed parts of the ear and nose using tissue phantoms are shown respectively; and Figures 9A to 9D The RDP concept for printing under an opaque housing is illustrated schematically, including the following steps: injection of printing material, formation of infill areas, printing at the desired location, and final curing of the part. Detailed Implementation

[0011] This invention relates to additive manufacturing, and more specifically, to acoustically triggered ultraactive microreactors (UAMRs) for providing remotely printed structures that can be printed under a robust and opaque shell via acoustically triggered UAMRs, which has industrial application value, particularly suitable for aerospace applications or media such as human / animal tissues.

[0012] The following description provides illustrative embodiments only and is not intended to limit the scope, applicability, or configuration of the disclosure. Rather, the subsequent description of the embodiments will provide those skilled in the art with instructions for implementing one or more embodiments of the invention. It should be understood that various changes to the function and arrangement of the elements may be made without departing from the spirit and scope set forth in the appended claims. Therefore, the embodiments are examples or implementations of the invention, and not the only implementations. The various expressions “one embodiment,” “a kind of embodiment,” or “some embodiments” do not necessarily refer to the same embodiment. Although various features of the invention may be described in the context of a single embodiment, these features may also be provided individually or in appropriate combinations. Conversely, although the invention may be described in the context of different embodiments for clarity, the invention may also be implemented in a single embodiment or any combination of embodiments.

[0013] The use of terms such as "an embodiment," "a kind of embodiment," "some embodiments," or "other embodiments" in the specification refers to the inclusion of a specific feature, structure, or characteristic in at least one embodiment, but not necessarily in all embodiments. The wording and terminology used herein should not be construed as restrictive, but are for descriptive purposes only. It should be understood that when the claim or specification refers to the element "an" or "a," this reference should not be construed as meaning that there is only one such element. It should be understood that when the specification states that a component, feature, structure, or characteristic "may," "may," "may," or "can" be included, that particular component, feature, structure, or characteristic is not necessarily included.

[0014] Terms such as “left,” “right,” “up,” “down,” “front,” and “back” are used relative to the orientation of specific features, structures, or elements of the embodiments described in the accompanying drawings. It is obvious that these directional terms have no specific meaning in the actual use of the device, as users may use the device from various different orientations.

[0015] References to the terms “comprising,” “including,” “consisting of,” and their grammatical variations do not preclude the addition of one or more components, features, steps, or integers or groups thereof, and these terms are not to be construed as specifying any component, feature, step, or integer. Similarly, the phrase “substantially constitutes” and its grammatical variations, when used herein, should not be construed as excluding additional components, steps, features, integers, or groups thereof, but rather as meaning that the additional features, integers, steps, components, or groups thereof do not substantially alter the fundamental and novel characteristics of the claimed composition, apparatus, or method. If the specification or claims refer to the element “additional,” this does not preclude the existence of multiple additional elements.

[0016] The term "CAD model" as used herein can refer to, but is not limited to, an electronic file containing information related to components, parts, elements, or assemblies to be manufactured. A CAD model can define an object in two-dimensional (2D) or three-dimensional (3D) space, and in addition to defining the object's internal and / or external geometry and structure, may also include information related to materials, processes, dimensions, tolerances, etc. In embodiments of the present invention, the CAD model can be generated as electronic content and transmitted to a manufacturing system provided according to one or more embodiments of the present invention. In other embodiments of the present invention, the CAD model can be directly derived from one or more electronic contents; for example, a 3D model can be created from a series of 2D images or extracted from electronic content.

[0017] As used in this article, "fluid" can refer to, but is not limited to, any substance that undergoes continuous deformation (flow) under applied shear stress. Fluids can include, but are not limited to, liquids, gases, plasmas, and some plastic solids.

[0018] As used herein, “powder” can refer to, but is not limited to, a dry, bulk solid composed of a large number of extremely fine particles that are free to flow when shaken or tilted. Powder can be defined by the material or combination of materials from which it is formed and by particle size (such as minimum particle size, maximum particle size, particle size distribution, etc.). Powder generally refers to granular materials with fine particle sizes, but can also include larger particle sizes, depending on the size of the part being manufactured and the characteristics of the additive manufacturing system.

[0019] The term "metal" as used in this article can refer to, but is not limited to, materials with good electrical and thermal conductivity. Metals typically possess ductility, fusibility, and toughness. The term "metal" as used in this article can refer to elements such as gold, silver, copper, aluminum, and iron, as well as alloys such as bronze, stainless steel, and steel.

[0020] As used in this article, "resin" can refer to, but is not limited to, solid or highly viscous substances that can typically be converted into polymers. Resins can be derived from plants or synthesized artificially.

[0021] The term "ceramics" as used in this article can refer to, but is not limited to, inorganic non-metallic solid materials composed primarily of metallic, non-metallic, or metalloid atoms bonded by ionic and covalent bonds. Such ceramics can be crystalline materials such as oxides, nitrides, or carbides, elements such as carbon or silicon, or amorphous materials.

[0022] As used in this article, "polymer" can refer to, but is not limited to, macromolecules or high molecular weight polymers composed of numerous repeating subunits. Such polymers can be natural or synthetic, and are typically produced through the polymerization of multiple monomers. Polymers, due to their large molecular weight, can provide unique physical properties, including toughness, viscoelasticity, and a tendency to form glassy and semi-crystalline structures rather than crystalline ones.

[0023] The term "insulator" as used in this article can refer to, but is not limited to, materials in which internal charges cannot flow freely, and therefore hardly generate current under the influence of an electric field.

[0024] As used herein, "robot" or "robot system" may refer to, but is not limited to, a mechanical system that provides motion control for one or more parts of a mechanical system under user or computer control. A robot has a framework, form, or shape designed to perform a specific task, and also has electrical components that provide power and control for the robot; some robots contain a set of computer-programmed code. Robots can be stationary or mobile and may include systems designed to mimic biological forms, such as humanoid robots.

[0025] As used herein, "energy source" can refer to, but is not limited to, an element in an additive manufacturing (AM) system that creates a transmitting signal according to or utilizing one or more embodiments of the present invention. An energy source can refer only to a portion of each element that generates the transmitting signal (e.g., a transducer), or it can refer to a portion or all of the control and drive circuitry associated with the element generating the transmitting signal and receiving control data, processing control data, and generating appropriate drive signals. An energy source can generate a transmitting signal selected from the group consisting of infrared (IR) radiation, visible light radiation, ultraviolet (UV) radiation, microwave radiation, radio frequency (RF) radiation, X-ray radiation, electron beam radiation, ultrasonic signals, acoustic signals, hypersonic signals, magnetic fields, or electric fields. While an energy source can refer to a single type of transmitting signal, other energy sources can also emit multiple signals. The physical size of an energy source can vary depending on the size of the AM system to which it belongs and the number of discrete transmitters in that AM system. Thus, an energy source can be picometer-sized (10⁻⁶) -12 m) or angstrom (10 -10 Picometer-scale elements with dimensions on the order of m, and nanometer-scale (10) -9 Nanoscale devices with dimensions on the order of m, and micrometers (10) -6 Micrometer-scale components with dimensions on the order of m, and those with dimensions on the order of millimeters (10). -12 m), centimeter (10 -2 m), meters (10 0 m) and ten meters (10 1 Components with dimensions on the order of m.

[0026] As used in this article, "X-wave" can refer to, but is not limited to, a wave or field generated by an energy source and propagating from that energy source through one or more media. Therefore, an X-wave can be an emitted wave or field selected from the group consisting of near-infrared (IR) radiation, far-infrared (IF) radiation, visible light radiation, ultraviolet (UV) radiation, microwave radiation, radio frequency (RF) radiation, X-ray radiation, electron beam radiation, ultrasonic signals, acoustic signals, hypersonic signals, and magnetic or electric fields.

[0027] As used in this article, “nanoparticles” or “ultrafine particles” can refer to, but are not limited to, particles of matter with diameters between 1 nanometer and 100 nanometers (nm). However, the term can also be used to refer to larger particles, such as particles with diameters up to 500 nm, or nanofibers (solid fibers with a length much greater than their cross-sectional dimensions) and nanotubes (hollow-core particles with a length much greater than their cross-sectional dimensions) that are less than 100 nm in only two directions.

[0028] As mentioned above, additive manufacturing (AM) processes are typically based on curing buildup materials pixel-by-pixel and layer-by-layer to create three-dimensional objects. Compared to traditional subtractive manufacturing (SM) processes based on material removal, AM processes are generally considered more material-efficient and have the potential to manufacture parts, especially single pieces and prototypes, at a lower cost. However, despite these advancements, light and heat remain the primary energy sources for polymerizing or depositing / melting printing materials in AM. This limits the penetration depth of the energy source within the medium of the cured printing material.

[0029] In contrast, volumetric printing (VP) has recently been introduced, in which a three-dimensional image of a desired object is created within a container filled with printing material, for example, see patent WO / 2018 / 1451947, "Method and System for Additive Manufacturing". Based on this, the inventors have established a novel printing paradigm called Remote Printing (RDP). Within RDP, for example, sound waves are used to induce a chemical reaction and drive the curing process of the printing material via an acoustic-chemical pathway in a sound wave-using scenario. The applicant employs a triggering mechanism compatible with chemical reaction triggering and transparent to the intermediate medium. The penetration depth of this triggering mechanism (i.e., the energy source) is flexibly adjustable and significantly improved compared to existing AM (Advanced AM) solutions.

[0030] In the following description, sound waves will be described and applied. However, within the scope of this invention, sound waves refer to a type of "X-wave," known as a wave or field generated by an energy source that propagates through one or more media to trigger a chemical reaction, thereby forming a printed object. Thus, the printed object can be embedded in one or more media. Therefore, the X-wave can be near-infrared (IR) radiation, far-infrared (IF) radiation, visible light radiation, ultraviolet (UV) radiation, microwave radiation, radio frequency (RF) radiation, X-ray radiation, electron beam radiation, ultrasonic signals, acoustic signals, hypersonic signals, magnetic fields, or electric fields. A suitable X-wave is determined based on whether the intermediate medium possesses the necessary transparency (e.g., such transparency limits unnecessary absorption by the intermediate medium or meets the power requirements of the energy source) and the triggering mechanism.

[0031] In the following description, the sound field can be, but is not limited to, a high-intensity focused ultrasound (HIFU) field or a low-intensity focused ultrasound (LIFU) field, and can be formed by using one or more energy sources to create sound fields of various shapes, which generate a target field based on their geometry, emission field shape, field amplitude, and field phase combination relative to other energy sources. As described in patent WO / 2018 / 1451947, the shape of the field and the position of the “focused” region can vary in space and time, thereby allowing the focused region to be translated in the medium, thus forming a three-dimensional (3D) printed object.

[0032] refer to Figure 1A and Figure 1B This illustrates the differences between light-based (photon) printing technology and embodiments of the present invention. (Reference) Figure 1A In opaque materials, the penetration depth of light is limited to submicron or submillimeter levels. However, when using sound fields, the penetration depth can reach millimeters, centimeters, and potentially even tens of centimeters. (Reference) Figure 1B Acoustic waves drive a sonochemical reaction. In this specification, the inventors may use the term "ultra-active microreactor" (UAMR) to refer to both the particles undergoing the chemical reaction and the region where the chemical reaction occurs. Generally, this term applies to the region where the desired 3D part is printed by moving the UAMR within a medium containing printing material or within the printing material itself. In some embodiments of the invention, the UAMR may be a small, localized region, allowing for the formation of small parts or miniature 3D components. In other embodiments of the invention, the UAMR may be a medium / large extended region. In embodiments of the invention, the UAMR may be created using one or more acoustic holograms and / or metamaterials. The UAMR may be translated by moving a transducer that generates an energy source or by using a phased array transducer system, as described in patent WO / 2018 / 1451947.

[0033] Figure 2A An exemplary printing configuration of an RDP according to an embodiment of the present invention is shown, including a HIFU transducer mounted on a motion manipulator, wherein a printing medium is arranged within a build chamber. A component is formed within the medium by appropriate movement of the manipulator and activation by the HIFU transducer. Figure 2B A visualization of the UAMR region is shown, which consists of high-pressure and low-pressure zones where chemically active microcavitary "bubbles" are generated, driving the curing process within the UAMR region. These microcavitary bubbles generate heat within the UAMR region, thereby curing the printing medium, such as thermosetting polymers like polydimethylsiloxane (PDMS).

[0034] The following section will provide application examples of RDP. Those skilled in the art will readily understand that the applications of RDP are not limited to those described herein.

[0035] Printing deep within opaque materials In traditional light-based AM technology, such as Figure 1A As shown, light absorption and scattering hinder light (i.e., printing energy) from penetrating the printing medium, especially when the printing material and / or the medium in which the printing material resides are opaque and / or filled with scattering particles. However, since sound waves (rather than light) are used as the energy source, such as Figure 1B As shown, the optical opacity of the printing material does not affect the RDP process. Attenuation and scattering of sound waves cause absorption and deflection, which is considered when configuring acoustic signals from acoustic transducers (e.g., HIFU and / or LIFU transducers) based on the printing material and / or the medium in which the printing material resides. However, due to the nature of sound waves, as long as attenuation and scattering do not dominate, light absorption and scattering will not affect the penetration depth of sound waves in optically opaque materials.

[0036] refer to Figure 3 The diagram illustrates first to fourth components 310 to 340 printed from opaque printing materials. Ultrasonic waves sequentially pass through 30 mm of water, a 1 mm solid barrier (i.e., the chamber wall containing the printing material), and 18 mm of the opaque printing material itself, ultimately reaching the platform forming the printed component. The first to fourth components 310 to 340 are respectively made of polydimethylsiloxane (PDMS) loaded with silica. SiO 2-PDMS), polydimethylsiloxane (PDMS) supported on silica / alumina (2-PDMS) SiO 2 / Al 2 O 3-PDMS), aluminum-supported polydimethylsiloxane ( Al -PDMS) and iron-loaded polydimethylsiloxane (PDMS) Fe-PDMS) formation. A colloidal solution of the opaque printing material is prepared for each printing of opaque micro / nano composite materials. Therefore, SiO 2. SiO 2 / Al 2 O 3. Al and Fe The powder is mixed with a PDMS polymer matrix. The printed parts, as green bodies, are then used for sintering in a furnace to prepare ceramic composites. Figure 4A The first to third sintered components 410 to 430 in the diagram show the sintered components respectively. SiO 2 / Al 2 O 3-PDMS Al -PDMS and Fe -PDMS green parts.

[0037] In order to form a shape for making green parts SiO 2 and SiO 2 / Al 2 O 3. Printing materials Figure 3 The first component 310 and the second component 320 are shown respectively. First, 7% by weight of silica or silica / alumina particles are mixed with 84.5% by weight of PDMS base material in a homogenizer for 1 hour, and then 8.5% by weight of curing agent is added and mixed for 15 minutes.

[0038] In order to form the printing material used to make green parts, Figure 3 The third component 330 and the fourth component 340 are shown respectively, which will contain 7% by weight Fe and Al Mix with 8.5% by weight of curing agent and ultrasonically agitate for 10 minutes. Then mix the prepared colloidal solution with 84.5% by weight of PDMS-based material for 30 minutes.

[0039] These polymer materials were used to prepare polymer ceramic green bodies, namely the first to fourth bodies 310 to 340, which were then sintered in a tube furnace at 1100°C under an argon atmosphere with a heating and cooling rate of 40°C / hour. Figure 4A The image shows the sintered product. SiO 2 / Al 2 O 3. Al and Fe Ceramic components.

[0040] Figure 4BThe X-ray diffraction (XRD) spectra of these ceramic components are shown, scaled to the background. Measurements were performed on an Empyrean system using copper radiation in a Bragg-Brentano reflective geometry. These ceramic components are amorphous, exhibiting broad peaks accompanied by a few weaker, sharper peaks.

[0041] exist Figure 4C In the middle, it can be identified Al -PDMS ceramic components SiC , Si , Al 2 O 3 and Al 2 O 3 .2SiO Two peaks, such as Figure 4C As shown, for Fe -PDMS sample, XRD data shows Fe 3 Si , Fe 2 and Fe 5 Si 3.

[0042] Figure 4D It shows Fe - Fourier transform infrared (FTIR) spectra of PDMSD before and after pyrolysis. Before pyrolysis Fe The peak distribution in the infrared (IR) spectrum of the PDMS sample (printed part) is 2950 cm⁻¹. -1 and 2820cm -1 ( and (extension and vibration), 1400cm -1 ( - (In-plane symmetrical deformation vibration), 1250cm -1 ( - (In-plane asymmetric deformation vibration), 1080cm -1 and 1015cm -1 ( (extensional vibration), 860cm -1 ( Out-of-plane deformation (swinging) vibration and 790cm -1 ( (Stretching vibration). Pyrolysis. Fe - PDMS peak distribution is 1100cm -1 and 1080cm -1 (in Si-O-Si groups) ) and 770cm -1 ( (Stretching vibration). CH absorption bands were visible in the sample before pyrolysis, but not at 2970 cm⁻¹ after pyrolysis. -1 It was detected at 1000 cm⁻¹ that siloxanes were present before and after pyrolysis. -1 A strong band is present nearby, with visible absorption peaks. Due to the presence of Fe, no intensity changes were observed in the Si-O and Si-C bands in the spectrum.

[0043] It is therefore evident that RDP has broad applications across multiple disciplines, ranging from remote repair or on-site maintenance of concealed components in the aerospace industry to remote in vivo bioprinting and non-invasive bioprinting of human organs and medical implants. Exemplary medical applications are outlined in the following description.

[0044] Printing deep inside the body The importance of combining printing technology with injectable biomaterials for in vivo printing was recognized approximately 20 years ago; for example, see Berg et al., "Minimally Invasive Tissue Engineering Composites and Cell Printing" (IEEE Journal of Engineering Medicine & Biomedicine, 2003, Vol. 22, pp. 84-91). However, current advanced bioprinting technologies require open surgery due to fundamental limitations in the methods used, which rely on heat or light as energy sources. Recently, near-infrared (NIR) sources have been successfully used for non-invasive printing of structures at depths of 0.5 mm subcutaneously. However, this low penetration depth limits bioprinting to submillimeter depths. In contrast, the properties of RDPs enable the creation of structures at depths ranging from millimeters to centimeters in vivo. Figure 5 A schematic diagram of an idealized RDP system for non-invasive surgery is shown, in which the printing process is integrated with the imaging system.

[0045] The inventor through Figure 6A The in vitro / ex vivo system illustrated demonstrates this concept, in which a structure is printed in PDMS, and a tissue phantom is positioned between the PDMS and a HIFU transducer located within a matching medium. In in vitro experiments conducted by the inventors, tissue phantoms simulating human skin and muscle were created, such as… Figure 6B As shown. The matching medium used in the experiment was water. The thickness of the tissue phantom was 6 mm. The thickness of the PDMS used was 18 mm, and the maximum total printing depth from the water-tissue phantom interface to the PDMS was 24 mm. Figure 6C A cross-section of a tissue phantom is shown, which includes 3 mm thick skin and 3 mm thick tissue. Figure 6D An image showing the printed object attached to a tissue phantom substrate within the printing chamber is shown.

[0046] The phantom consists of three layers, simulating the epidermis, dermis, and subcutaneous tissue of real skin tissue. The subcutaneous tissue solution was prepared by dissolving 2% (w / v) gelatin and 0.2% (w / v) agar in 80 ml of distilled water, gradually adding 15% (w / v) bovine serum albumin (BSA), and finally mixing with 1% (w / v) silica. The dermal simulation layer was prepared by mixing 1% (w / v) agar, 24% (w / v) gelatin, 35% (w / v) BSA, and 0.5% (w / v) silica microspheres in 80 ml of distilled water. The epidermal solution was prepared by mixing 5% (w / v) glycerol, 10% (w / v) gelatin powder, and 0.1% (v / v) glutaraldehyde. The 50 ml solution used to prepare the muscle tissue phantom was prepared by mixing 40% (v / v) condensed milk, 2% (w / v) silica powder, 2% (w / v) agar and 60% (v / v) distilled water.

[0047] In the in vitro experiments, the inventors used methods such as Figure 7A The pig tissue shown includes 3 mm thick skin, 10 mm thick fat, and 2 mm thick muscle. In these experiments, the ultrasound signal needed to penetrate 15 mm thick tissue (skin, fat, and muscle) and up to 18 mm thick PDMS, achieving a printing depth of 33 mm. Figure 7B An example printed object is shown.

[0048] Figure 8A The computer-aided design (CAD) model 800A of the ear is shown, along with the printed ear 850A. Figure 8B The computer-aided design (CAD) model 800B of the nose is shown alongside the printed nose 850B. From Figures 6A-6D , Figures 7A-7B and Figures 8A-8B It can be seen that RDP allows for non-invasive deep-body printing.

[0049] Printing deep beneath the barrier Figures 6A-8B The experiments shown illustrate the printing process under an opaque layer or shell (muscle-tissue-skin-fat). However, in other embodiments of the invention, the opaque layer can be a shell made of materials such as metal, plastic, or ceramic. See also Figure 9A The image shows a base layer with a shell on top, through which printing material is injected. (Example:) Figure 9B As shown, the printing material accordingly fills the gap between the shell and the substrate. Then, as... Figure 9CAs shown, the sound source is positioned outside the housing, creating a UAMR region within the printing material, which then cures the printing material beneath the housing. Moving the energy source creates multiple chemically active regions, thus creating a series of cured regions, ultimately forming the desired object beneath the housing. Figure 9D As shown.

[0050] In other embodiments of the invention, for example, RDP can print 3D objects behind skin, muscles, fat, and bones.

[0051] According to embodiments of the present invention, at least one of the porosity of the 3D object region and the pore size of the porous region of the 3D object is adjusted based on one or more properties of the printing material.

[0052] According to an embodiment of the present invention, at least one of the following is adjusted based on the external pressure applied to the printing material: the porosity of the 3D object region, the size of the pores within the region, and whether the pores are interconnected or disconnected.

[0053] According to an embodiment of the present invention, the porosity of the 3D object region, the size of the pores within the region, and whether the pores are interconnected or disconnected are adjusted based on at least one of the motion speed and acceleration of one or more energy sources during the region formation process.

[0054] According to an embodiment of the present invention, the printing material is a resin selected from liquid resin, composite resin and resin slurry, wherein the resin matrix is ​​a resin matrix of at least one polymerized resin obtained through a free radical polymerization mechanism and a thermal cutting process.

[0055] According to an embodiment of the present invention, the pressure field is moved by adjusting the phase of the pressure field generated by one or more sound sources, including adjusting the characteristics of one or more phased array transducers, thereby adjusting the pressure field within the printing material.

[0056] According to an embodiment of the present invention, the pressure field is moved by adjusting the phase of the pressure field generated by one or more sound sources, including adjusting the properties of at least one of an active acoustic hologram and a metamaterial in real time during the printing process, thereby adjusting the pressure field within the printing material.

[0057] According to embodiments of the present invention, printing material is delivered to a region of the body via a fluid within the body (e.g., saliva, blood, etc.), wherein the printing material generates a printed object by exposing that region to an energy source. The energy source can be selected from emitted waves or fields, chosen from the group consisting of microwave radiation, radio frequency (RF) radiation, X-ray radiation, electron beam radiation, ultrasonic signals, acoustic signals, hypersonic signals, magnetic fields, or electric fields. The printing material can be added to a fluid, flow through one or more body regions, and then be removed from the body, for example, by filtration. For example, a stent can be formed directly within an artery or vein. In another example, a coating can be formed on the surface of arteries, veins, bones, etc.

[0058] According to embodiments of the present invention, the printing material is at least one of a thermosetting polymer, a biocompatible resin, a thermosetting polymer composite material, or a thermosetting biocompatible ink loaded and dispersed within a carrier. In embodiments of the present invention, the carrier contains at least one or more types of living cells.

[0059] According to embodiments of the present invention, a method is provided for forming a three-dimensional (3D) object by inserting one or more energy sources into a target body, wherein the one or more energy sources trigger a series of UAMR regions in a printing medium within the target body, thereby forming at least one 3D object within the target body and / or on the surface of the target body. The one or more energy sources can be moved to move the activated regions within the target body.

[0060] For example, the target body can be a region of the human or animal body, such as arteries, veins, mouth, ear, nose, pharynx, lungs, vagina, heart, capillaries, and urethra. One or more power sources can be mounted on or form part of a flexible or rigid device, which moves under the instruction of at least one of the user and the robotic system. The flexible device may include, but is not limited to, catheters or endoscopes. The flexible or rigid device may include one or more fluid channels for dispensing printing media in the vicinity of one or more power sources. The flexible or rigid device may include one or more other fluid channels for removing one or more substances and / or byproducts generated by UAMR.

[0061] The 3D manufacturing process can be controlled in a closed-loop manner through external and / or internal observation systems such as endoscopes, ultrasound imaging, and magnetic resonance imaging.

[0062] In embodiments of the present invention, the 3D manufacturing process can manufacture one or more of the following in situ within living tissue: body parts, a portion of a body part, medical implants, attachments to medical implants, repair medical implants, biocompatible structures, circuits, muscles, cartilage, body tissues, and subcutaneous tattoos.

[0063] In embodiments of the present invention, UAMR can be used to trigger one or more subsequent processes to remove substances from the surface or interior of living tissue, including, but not limited to, tattoo removal, dental plaque removal, and atherosclerosis treatment.

[0064] In embodiments of the present invention, the printing material activated by UAMR can form resin, plastic, metal, alloy, ceramic, composite material, biocompatible composite material, conductive material, insulator, magnetic material, material with fluorescent properties, and biomaterial capable of detecting one or more properties (including, but not limited to, glucose and hormones).

[0065] Those skilled in the art will readily understand that the method can be widely applied in various fields, including medicine, veterinary medicine, aerospace, transportation systems, or vehicles.

[0066] Specific details have been set forth in the foregoing description to provide a thorough understanding of the embodiments. However, it should be understood that the embodiments may be practiced without these specific details. For example, circuits may be shown in block form to avoid obscuring the embodiments with excessive detail. In other cases, well-known circuits, processes, algorithms, structures, and techniques may be shown without unnecessary detail to avoid obscuring the embodiments.

[0067] Furthermore, it should be noted that an embodiment can be described as a process, which may be presented in the form of a flowchart, diagram, data flow diagram, structure diagram, or block diagram. While a flowchart can describe operations as a sequential process, many operations can be performed in parallel or simultaneously. Moreover, the order of operations can be rearranged. When an operation is completed, the process terminates, but there may be other steps not included in the diagram. A process can correspond to a method, function, program, subroutine, group of subroutines, etc. When a process corresponds to a function, its termination corresponds to the function returning to the calling function or the main function.

[0068] The foregoing disclosure of exemplary embodiments of the present invention is for illustrative and descriptive purposes only. It is not intended to exhaustively cover the entire scope of the invention or to limit the embodiments to the precise forms described herein. Many variations and modifications of the embodiments described herein will be apparent to those skilled in the art based on the foregoing disclosure. The scope of the invention is defined only by the appended claims and their equivalents.

[0069] Furthermore, in describing representative embodiments of the invention, the specification may present the methods and / or processes of the invention as a specific sequence of steps. However, the method or process should not be limited to the specific sequence of steps described herein, where the method or process does not depend on it. Other sequences of steps may also be employed, as will be understood by those skilled in the art. Therefore, the specific sequence of steps set forth in the specification should not be construed as a limitation on the claims. Moreover, the claims relating to the methods and / or processes of the invention should not be limited to performing their steps in the written order, and those skilled in the art will readily understand that the sequence of steps can be varied and remains within the spirit and scope of the invention.

Claims

1. A method of forming a three-dimensional (3D) object, comprising: providing one or more acoustic sources configurable to generate a pressure field within a printing material, the pressure field comprising at least one of a focused pressure field and an unfocused pressure field; and moving the pressure field by moving at least one of a subset of the one or more acoustic sources, or adjusting a phase of the pressure field generated by the one or more acoustic sources; wherein the pressure field generated by the one or more acoustic sources triggers formation of a high chemical activity region within the printing material, thereby solidifying a portion of the printing material, whereby the 3D object is formed by moving the pressure field.

2. The method of claim 1, wherein the 3D object formed within the printing material comprises at least one of a porous portion and a non-porous portion.

3. The method of claim 1, wherein the printing material is opaque; and the 3D object is printed deep within the printing material.

4. The method of claim 1, wherein at least one of: the printing material is at least one of a thermoset polymer, a biocompatible resin, a thermoset polymer composite, or a thermoset biocompatible ink loaded within a carrier; and the printing material is at least one of a thermoset polymer, a biocompatible resin, a thermoset polymer composite, or a thermoset biocompatible ink loaded and dispersed within a carrier, the carrier comprising at least one or more living cells.

5. The method of claim 1, wherein at least one of a bone, skin, fat, and muscle of a human and an animal is located between the printing material and the one or more acoustic sources.

6. The method of claim 1, wherein a housing is disposed between the printing material and the one or more acoustic sources, and the printing material is not directly accessible.

7. The method of claim 1, wherein at least one of a porosity of the 3D object region and a pore size within a porous region of the 3D object is adjusted according to one or more properties of the printing material.

8. The method of claim 1, wherein at least one of a porosity of the 3D object region, a size of the pores within the region, and whether the pores are interconnected or disconnected is adjusted according to an external pressure applied to the printing material.

9. The method of claim 1, wherein at least one of a porosity of the 3D object region, a size of the pores within the region, and whether the pores are interconnected or disconnected is adjusted according to at least one of a velocity and an acceleration of movement of one or more energy sources during formation of the region.

10. The method of claim 1, wherein the printing material is a resin selected from a group consisting of a liquid resin, a composite resin, and a resin slurry, wherein a resin matrix of the resin is polymerized by at least one of a free radical polymerization mechanism and a thermal cutting process.

11. The method of claim 1, wherein ​ moving the pressure field by adjusting a phase of the pressure field produced by the one or more sound sources, including adjusting a characteristic of one or more phased array transducers.

12. The method of claim 1, wherein, moving the pressure field by adjusting a phase of the pressure field produced by the one or more sound sources, including adjusting a characteristic of at least one of an active acoustic hologram and a metamaterial in real-time during the printing process.

13. A method of forming a three-dimensional (3D) object, comprising: providing one or more energy sources configurable to produce a region of a trigger chemistry region within a printing material; and moving the region by moving at least one of the one or more sound sources or adjusting a phase of the pressure field produced by the one or more sound sources; wherein, the region produced by the one or more energy sources triggers a formation of a high chemical activity region within the printing material, thereby solidifying a portion of the printing material, whereby the 3D object is formed by moving the region.

14. The method of claim 13, wherein, each of the one or more energy sources is a source of microwave radiation, a source of radio frequency (RF) radiation, a source of X-ray radiation, a source of electron beam radiation, a source of ultrasonic signals, a source of acoustic signals, a source of hypersonic signals, a source of magnetic field, or a source of electric field.

15. A method of forming a three-dimensional (3D) object within a target body, comprising: inserting one or more energy sources within the target body, wherein the one or more energy sources trigger a series of ultra-active micro-reactor (UAMR) regions (activation regions) in a printing medium within the target body; wherein, the 3D object is located within the target body or on a surface of the target body; and the one or more energy sources can be moved, thereby moving the activation regions within the target body.

16. The method of claim 15, wherein, the target body is one of a human body region and an animal body region.

17. The method of claim 15, wherein, the target body is one of an artery, a vein, a mouth, an ear, a nose, a throat, a lung, a vagina, a heart, a capillary, and a urethra.

18. The method of claim 15, wherein, the one or more energy sources are mounted on or form part of a flexible device or a rigid device; and the flexible device or the rigid device is moved under an indication of at least one of a user and a robotic system.

19. The method of claim 15, wherein, the one or more energy sources are mounted on or form part of a catheter or an endoscope.

20. The method of claim 19, wherein, the flexible device or the rigid device includes at least one of: one or more fluid channels for dispensing a printing medium in a vicinity of the one or more energy sources; and one or more other fluid channels for removing at least one of a substance and a byproduct in a series of UAMR processes.

21. The method of claim 15, wherein, ​ The movement of the one or more energy sources relies on a control loop that employs at least one of an external observation system and an internal observation system.

22. The method of claim 21, wherein, When the control loop employs an internal observation system, it is an endoscope; and When the control loop employs an external observation system, it is ultrasound imaging or magnetic resonance imaging.

23. The method of claim 15, wherein, The 3D object is formed in situ within living tissue; and The 3D object is at least one of: a body part, a portion of a body part, a medical implant, an addition to a medical implant, a prosthetic medical implant, a biocompatible structure, an electrical circuit, a muscle, cartilage, body tissue, a subdermal tattoo.

24. The method of claim 15, wherein, The series of UAMRs trigger one or more subsequent processes to remove a substance from a surface or interior of living tissue.

25. The method of claim 15, wherein, The printing material, upon activation by the series of UAMRs, is at least one of: a resin, a plastic, a metal, an alloy, a ceramic, a composite material, a biocompatible composite material, an electrically conductive material, an insulator, a magnetic material, a material with fluorescent properties, and a biological material capable of detecting one or more properties.

Images