Direct Sound Printing (DSP) is a transformative additive manufacturing platform that uses patterned ultrasound waves to direct polymerization and solidify materials at precise locations deep within otherwise inaccessible environments. Unlike traditional 3D printing techniques that rely on optical or thermal energy and require direct line-of-sight access, DSP leverages acoustic energy fields to fabricate structures through opaque barriers, including biological tissue. This emerging approach introduces a new paradigm for noninvasive, in-body bioprinting and remote additive manufacturing. The presentation will detail the working principles and strategies underlying DSP, including ultrasound-induced cavitation chemistry, acoustic focusing, and real-time control of localized energy deposition. Case studies will highlight successful demonstrations of polymer crosslinking and 3D construct formation within scattering media mimicking biological tissue. Examples include the formation of scaffolds for bioadhesives, tissue regeneration, tissue-compatible hydrogels, and encapsulation of bioinks containing living cells under minimally invasive conditions. Beyond biomedical applications, the session will explore the broader implications of DSP in hazardous, enclosed, or remote environments, where conventional additive manufacturing cannot operate, such as underwater repairs, confined mechanical systems, or space habitats. Strategies for scaling, process monitoring, and integration with robotic or imaging systems will also be discussed. By transforming ultrasound from a diagnostic and therapeutic modality into a fabrication tool, DSP bridges the gap between manufacturing and medicine. The talk will conclude with a discussion of regulatory and translational pathways, potential clinical workflows, and future directions toward hybrid acoustic-optical manufacturing platforms. This presentation will appeal to researchers, engineers, and industry leaders seeking next-generation additive manufacturing technologies that extend the reach of fabrication beyond the visible and accessible, opening new frontiers for noninvasive, in-body, and remote 3D printing.
Learning Objectives:
Upon completion, participants will be able to describe how Direct Sound Printing enables noninvasive, deep in-body fabrication using focused and patterned ultrasound waves.
Upon completion, participants will be able to identify biomedical and industrial applications of Direct Sound Printing for tissue repair and remote additive manufacturing.
Upon completion, participants will be able to understand the technological principles, material strategies, and process control methods underlying ultrasound-induced polymerization in Direct Sound Printing.
