Dispensing Volumetric Additive Manufacturing

Abstract

Despite the advantages of additive manufacturing (AM) in creating customized 3D shapes, conventional layer-by-layer approaches are limited by low production rates, restricting their broader applications. Volumetric additive manufacturing (VAM) has emerged as a promising technique, enabling the simultaneous photopolymerization of entire volumes, which significantly reduces fabrication time. However, current computed axial lithography requires manual operations per print cycle, such as loading resin into a vial, physically placing and aligning the vial (with or without an index-matching medium), and removing the printed object, limiting continuous, high-throughput production of multiple parts. Here, we propose a dispensing volumetric additive manufacturing (DVAM) method that prints and dispenses each part within a droplet in less than a minute. The printing process occurs within a single droplet dispensed from a glass pipette, enabling simultaneous printed object removal and resin replenishment in a second. Light pattern distortion caused by the absence of the index-matching fluid was corrected through real-time droplet profile estimation and inverse ray-tracing within the optical system. We demonstrate rapid serial VAM of 10 different objects within 10 min. This approach establishes a practical pathway toward scalable, high-throughput volumetric manufacturing, enabling rapid production of complex 3D structures without the operational bottlenecks of conventional VAM workflows.