Fast and precise microdevice production enabled by sound-driven 3D printing

Researchers at Concordia University have developed a 3D printing technique that uses focused ultrasound to fabricate microscale structures on soft polymers, with a precision up to 10 times finer than that of previous sound-based methods.

The technique – called proximal sound printing – uses focused ultrasound to trigger chemical reactions. These solidify liquid polymers at targeted locations. 

Unlike conventional methods that rely on heat or light, the sound-based approach works with silicone and other materials commonly used in microfluidic devices, lab-on-chip systems, and soft electronics that have until now been difficult to print at small scales.

The method builds on the research team’s earlier work in direct sound printing, which first demonstrated that ultrasound could cure polymers on demand. That earlier technique struggled with limited resolution and consistency. 

The new proximal approach positions the sound source much closer to the printing surface, enabling tighter control over feature formation.

The researchers produced features up to 10 times smaller than previous methods while using significantly less power and improving repeatability. The improved precision enabled them to print complex microfluidic channels, flexible sensors, and multi-material structures in a single process.

Looking forward, the method could support faster prototyping of medical diagnostic devices, wearable technologies, and soft robotic components. It potentially offers manufacturers a simpler and more versatile production pathway for microscale systems used in health care, environmental monitoring, and advanced sensor applications.