New sound-based 3D-printing method enables 10× finer prints

Researchers at Concordia University have achieved a significant breakthrough in micro-manufacturing with the development of proximal sound printing (PSP). Published in the journal Microsystems & Nanoengineering, this new technique uses focused ultrasound to solidify liquid polymers with ten times the precision of previous acoustic methods.

The process builds on the team’s earlier work in direct sound printing, which utilized ultrasound to trigger sonochemical reactions. While the original method proved that sound could cure polymers on demand, it often struggled with resolution and consistency. By moving the sound source much closer to the printing surface, the "proximal" approach allows for tighter control and smaller feature sizes, all while consuming significantly less power.

Unlike traditional 3D printing that relies on heat or light, sound-based printing is uniquely compatible with soft materials like silicone, which are essential for lab-on-a-chip systems and wearable technologies but notoriously difficult to print at micro-scales.

The research — led by PhD graduate Shervin Forough — Professor Muthukumaran Packirisamy, and Mohsen Habibi, was supported by the Natural Sciences and Engineering Research Council. Looking forward, the team expects this technique to accelerate the prototyping of medical diagnostic devices and soft robotic components, offering a faster and more versatile alternative for manufacturing high-tech microscale systems.