Resin-based additive manufacturing offers high precision and surface quality relative to other 3D printing methods. However, manual support removal remains a significant bottleneck, as it limits part geometries, generates substantial plastic waste, and increases production costs. We present Selective Solubility Vat Photopolymerization (SSVP), a new dual-wavelength 3D printing process that enables automated support removal and closed-loop material recycling.
SSVP uses a single resin and two wavelengths of light - visible and ultraviolet - to control which regions remain solid and which later dissolve away. Visible light drives free radical polymerization to form a linear, dissolvable thermoplastic, while ultraviolet light triggers both free radical and cationic polymerization to produce a crosslinked, insoluble thermoset. When printed together, this enables the creation of intricate, support-intensive geometries that can be post-processed without manual labor. After printing, mild solvents selectively dissolve the thermoplastic supports, leaving the thermoset structure intact. Furthermore, the printed support structures can be dissolved into their constituent monomer and recycled directly back into printable resin, minimizing waste and enabling on-site, closed-loop material use. SSVP thereby opens new possibilities for automated fabrication in applications such as complex assemblies, dentistry, audiology, investment casting, and more.
Learning Objectives:
Upon completion, participants will be able to describe how dual-wavelength photopolymerization enables selective curing of dissolvable and permanent regions in a single-resin system.
Upon completion, participants will be able to understand how selective solubility can automate resin 3D printing workflows by eliminating manual support removal and enabling closed-loop material reuse.
Upon completion, participants will be able to identify potential industrial applications of dissolvable-support resin printing, including dentistry, audiology, and other industries.
