3D Printing Macroscale Engineered Materials Using Ultrasound Directed Self-Assembly and Stereolithography

A manufacturing process to 3D print engineered materials comprised of a user-specified pattern of nano-or microparticles embedded in a polymer matrix material is described. The materials are printed layer-by-layer using stereolithography, and in each layer, ultrasound directed self-assembly is employed to organize a user-specified pattern of particles. This process allows manufacturing macroscale 3D materials with a user-specified microstructure consisting of particles of any material, and contrasts with existing processes, which are often limited to laboratory scale, specific materials, and/or 2D implementations. Using this manufacturing process, 3D printing of macroscale multilayer engineered materials containing a Bouligand microstructure commonly found in composite laminate and biological materials is demonstrated. Additionally, engineered materials containing a pattern of electrically conductive nickel-coated carbon fibers are fabricated, which illustrate the feasibility of 3D printing structures with embedded insulated electrical wiring. This process finds application in manufacturing of multifunctional composite materials.