Emerging Continuous Light-based Volumetric 3D Printing Methods

At the Programmable Biomaterials Lab (PBL), our goal is to solve some of the major challenges facing large-scale and high-throughput bioproduction via innovative 3D light-assisted programming of matter. We envision a future where objects are produced, mechanisms triggered and materials handled purely by photons. We’re here to perfect our engineering and scientific prowess in harnessing this massive potential. We are part of the Mathematical and Physical Sciences (MAPS) Faculty, based at the UCL Institute for Materials Discovery (IMD), a focal point of materials research at UCL across all departments. The IMD strives to be at the forefront of advanced materials research and teaching. We run state-of-the-art experimental and computational facilities across UCL’s Bloomsbury and UCL East campuses. We are pioneering novel data-driven approaches for materials discovery, understanding fundamental materials behaviour, developing innovative sustainable materials for new innovative applications and boosting enterprise (i.e., industry) oriented materials research.

Microfluidic assembly techniques provide a new platform for creating novel polymer objects from photopolymerizable resins and hydrogels. In most cases, these objects are produced by co-flowing immiscible liquids through a microfluidic device that induces droplet break off yielding one object at a time in a sequential fashion. Due to surface-tension effects, only spherical shapes were readily produced until another technique named stop-flow lithography (SFL) enabled a rich array of complex shapes to be produced, in parallel, and high throughput. However, these objects are 2D by nature or limited by the cross section of the fluidic channel they pass through.

In 2019 we demonstrated a method for manufacturing objects by rotating a photopolymer in a dynamically evolving light field. This allowed us to print entire complex objects through one complete revolution, circumventing the need for layering. The method was particularly useful for high-viscosity photopolymers and fast contact-free fabrication. This PhD project aims to deliver a volumetric SFL and continuous flow lithography process for the first time ever. You will be designing the hardware, projections, and the resin chemistry that will enable this process through your PhD research at the PBL.

You will conduct research in the field of optical biomaterials, additive manufacturing and microfluidics, including synthesis and characterization of biocompatible polymers and hydrogels for the V-SFL system, developing, building and testing innovative microfluidic optical printing systems. You will deliver and report on your project results including in major journals, conferences and workshops. The position is centred at our new UCL East campus but will offer opportunities to engage in UCL Bloomsbury campus in central London.