Laser-assisted 3D Printing Revolutionizes Thermoset Electronics Fabrication
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A new laser-based 3D printing technique dramatically accelerates the creation of free-standing thermoset devices, potentially unlocking advancements in flexible electronics, soft robotics, and biocompatible medical devices.
Thermosets-durable, heat-resistant polymers like epoxy and silicon rubbers-are essential materials in numerous applications, from adhesives and coatings to electronic components. However, conventional 3D printing methods struggle to create complex, self-supporting structures with these materials due to lengthy curing times and the need for temporary support structures. Now, researchers at Xiamen university, university of California, Berkeley, and collaborating institutions have developed a groundbreaking approach that bypasses these limitations.
The innovative method, detailed in a recent paper published in Nature Electronics, combines direct ink writing with a laser-assisted solidification process. By integrating a 1,064-nm laser focused on the polymer ink jet,the team achieves in situ curing,enabling the construction of 3D structures without the need for supporting materials. “Standing thermoset devices offer two unique advantages,” stated another senior author. “First, the in-situ laser curing process eliminates the scheme used in conventional 3D processes by the supporting materials and post-process to remove the supporting structures. This enables the efficient fabrication of complex 3D geometries and broader device functionality. Second, the properties of printed 3D structures are programmable. For example, the local mechanical stiffness and electrical conductivity can be adjusted by the printing parameters so that different regions can be made softer or stiffer, and their conductivity can be high or low.”
The ability to tailor material properties opens exciting possibilities for creating devices with customized functionality. As a notable example, researchers envision comfortable wearable electronics with varying degrees of flexibility or robots with joints that can conduct electricity selectively. “To tailor the structures’ properties, we focus a 1,064-nm laser on the polymer jet near the nozzle tip, where the in-situ localized gelation of the thermoset ink is induced based on the photothermal affect,” explained a researcher involved in the study.
Demonstrating Versatility with Diverse Materials
To showcase the potential of their method, the researchers successfully printed a variety of free-standing devices using different thermoset materials, including PDMS, Dragon Skin, and Ecoflex.These devices included stretchable electronic components, soft sensors, and even 3D magnetic robots. The process achieves a printing resolution as fine as 50 µm and is adaptable for a wide range of applications.
According to researchers, the technique produces “high-resolution, free-standing architectures from diverse thermoset inks without additional support materials or prolonged post-processing.” By carefully controlling laser power and printing parameters, they can manipulate the Young’s modulus along the filament, creating stiffness gradients and spatially programmable functionality. This allows for the “volumetric programming of properties, such as mechanical stiffness and electrical conductivity.”
Future Implications and Scalability
The researchers believe this 3D printing strategy could pave the way for the large-scale manufacturing of new and diverse flexible electronic devices. Beyond soft robotics,the technology holds promise for the scalable production of organ-on-chip systems and biocompatible devices with advanced functionalities and complex 3D geometries.
“We now plan to build a robust 3D-printing platform for the construction of soft, multi-functional devices,” added a researcher. “We will also expand the printable ink toolbox and investigate the optimal printing parameters toward industrial applications, such as flexible electronics, organ chips and so on.”
This innovative approach represents a significant leap forward in 3D printing technology, offering a faster, more versatile, and more efficient method for creating complex thermoset-based devices.
More information:
Qibin Zhuang et al, Laser-assisted direct three-dimensional printing of free-standing thermoset devices, Nature Electronics (2025). DOI: 10.1038/s41928-025-01491-2.
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