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Sustainable Vat Photopolymerization of Complex Functional Structures

Vat photopolymerization (VPP)-based 3D printing technology boasts the capability of manufacturing 3D structures with remarkable complexity, precision, and rapidity. However, the necessity for additional supports in creating intricate features like overhangs or hollow sections poses a challenge, as these supports are not readily removable and often require laborious manual extraction, risking unintended damage and surface flaws. Here, a fast-dissolving and recyclable thiol-ene photopolymer specifically tailored for printing supports via multi-material VPP has been developed. Extensive investigation into the effects of surface-area-to-volume ratio and grayscale projection on recycling rates aims to minimize support dissolution time, thereby shortening the manufacturing cycle for complex structures. Optimized porous channels and gyroid structures in the supports render them highly removable and recyclable with the latter achieving a dissolution rate 50 times faster than that of solid supports.



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