Methods and systems for remote printing

Abstract

This invention introduces a new concept to additive manufacturing (AM) by enabling remote printing without direct access to the printing location. Heat and light, common energy sources in AM, have limited penetration into optically opaque media. However, this invention introduces deep penetration access to the printing medium by using acoustic waves. Acoustic wave patterns create chemically active regions where the printing material solidifies. The printing material may be a thermosetting polymer or polymer composite. This concept introduces a new paradigm for non-invasive / minimally invasive bioprinting within the body, without the need for open surgery, and is experimentally demonstrated in this patent. In addition, a new concept is introduced for printing under a solid, opaque shell, particularly in industrial applications in the aerospace sector, where printing is individually produced at smaller dimensions than currently achieved.

Claims

1. A method for forming a three-dimensional (3D) object, The steps include preparing one or more acoustic sources that can be configured to generate a pressure field including at least one of a focused pressure field and a non-focused pressure field within the printing material, The steps of moving the pressure field by moving at least one of the subsets of the one or more sound sources, or by adjusting the phase of the pressure field generated by the one or more sound sources, Includes, A method wherein the pressure field generated by one or more sound sources triggers the generation of highly chemically active regions within the printing material, thereby solidifying a portion of the printing material, and the moving pressure field forms a 3D object.

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

3. The printing material is opaque. The method according to claim 1, wherein the 3D object is printed in the depths of the printing material.

4. The printing material is at least one of a thermosetting polymer, a biocompatible resin, a thermosetting polymer composite, and a thermosetting biocompatible ink supported on a carrier. The printing material is at least one of a thermosetting polymer, a biocompatible resin, a thermosetting polymer composite, and a thermosetting biocompatible ink supported on a carrier containing one or more types of living cells. The method according to claim 1, which satisfies at least one of the following conditions.

5. The method according to claim 1, wherein at least one of the bones, skin, fat, and muscle of at least one of a human and an animal is placed between the printing material and the one or more sound sources.

6. The method according to claim 1, wherein a shell is positioned between the printing material and the one or more sound sources, preventing direct access to the printing material.

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

8. The method according to claim 1, wherein at least one of the porosity of a region of the 3D object, the dimensions of the pores within the region, and whether the pores are in communication with each other is adjusted in accordance with an external pressure applied to the printing material.

9. The method according to claim 1, wherein at least one of the porosity of a region of the 3D object, the dimensions of the pores within the region, and whether the pores communicate with each other is adjusted according to at least one of the velocity and acceleration of the motion of one or more energy sources during the formation of the region.

10. The method according to claim 1, wherein the printing material is a resin selected from liquid resins, composite resins, and resin slurries, and the resin matrix of the resin is polymerized via at least one of a free radical polymerization mechanism and a thermal cleavage process.

11. The method according to claim 1, wherein the step of shifting the pressure field by adjusting the phase of the pressure field generated by the one or more sound sources includes adjusting the characteristics of one or more phase array transducers.

12. The method according to claim 1, wherein the step of shifting the pressure field by adjusting the phase of the pressure field generated by the one or more acoustic sources includes adjusting the properties of at least one of the active acoustic hologram and the metamaterial in real time during the printing process.

13. A method for forming a three-dimensional (3D) object, The steps include preparing one or more energy sources that can be configured to generate regions that trigger chemical regions within the printing material, The steps of moving the region by moving at least one of a subset of one or more sound sources, or by adjusting the phase of the pressure field generated by one or more sound sources, Includes, A method wherein the region generated by one or more energy sources triggers the generation of highly chemically active regions within the printing material, thereby solidifying a portion of the printing material, and the moving region forms a 3D object.

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

15. A method for forming a three-dimensional (3D) object within a target body, A step of inserting one or more energy sources into a target body, wherein the one or more energy sources trigger a series of ultra-high activity microreactor (UAMR) regions (activation regions) within a printing medium placed in the target body. Includes, The 3D object is formed on at least one of the inside of the object and on the surface of the object, A method by which the one or more energy sources can be moved within the target body to move the activated region.

16. The method according to claim 15, wherein the object is either a region of a human body or a region of an animal body.

17. The method according to claim 15, wherein the target body is any of the arteries, veins, oral cavity, ear, nose, throat, lung, vagina, heart, capillaries, and urinary tract.

18. The one or more energy sources are attached to a flexible device or a rigid device, or constitute part of a flexible device or a rigid device. The method according to claim 15, wherein the flexible or rigid device is moved under the direction of at least one of the user and the robotic system.

19. The method according to claim 15, wherein the one or more energy sources are attached to or constitute part of a catheter or endoscope.

20. The aforementioned flexible or rigid device is One or more fluid channels for distributing the printing medium near the one or more energy sources, One or more other fluid channels for removing at least one of the by-products and substances of a series of UAMRs, The method according to claim 19, comprising at least one of the above.

21. The method according to claim 15, wherein the one or more energy sources are moved in accordance with a control loop using at least one of an external observation system and an internal observation system.

22. The control loop is an endoscope when an internal observation system is used. The method according to claim 21, wherein the control loop is ultrasonic imaging or magnetic resonance imaging when an external observation system is used.

23. The formation of the aforementioned 3D object is carried out in situ within biological tissue. The method according to claim 15, wherein the 3D object is at least one of a body part, a part of a body part, a medical implant, an addition to a medical implant, a repair of a medical implant, a biocompatible structure, an electrical circuit, muscle, cartilage, body tissue, and a subcutaneous tattoo.

24. The method according to claim 15, wherein the series of UAMRs trigger one or more subsequent processes that result in the removal of a substance from within or on the surface of a biological tissue.

25. The method according to claim 15, wherein the printing material after activation through the series of UAMRs is any of the following: resin, plastic, metal, alloy, ceramic, composite material, biocompatible composite material, electrically conductive material, insulator, magnetic material, material having fluorescent properties, and biomaterial that assists in the detection of one or more properties.

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