Researchers develop ultra-fast nature-inspired 3D printing method

According to the Beckman Institute for Advanced Science and Technology, researchers have developed a novel 3D printing process called ‘growth printing’ that mimics tree growth to create polymer parts quickly and affordably—without molds or costly equipment. Their findings appear in Advanced Materials.

“Completely new manufacturing processes are hard to find. Growth printing is entirely new, which is thrilling,” said Sameh Tawfick, a mechanical engineering professor at the University of Illinois Urbana-Champaign.

Traditional industrial manufacturing relies on injection molding, which is efficient for mass production but costly for maintenance, particularly for large objects like boat hulls. Additive manufacturing is mold-free but generally slow. “Our goal was to increase the manufacturing speed, size, and material quality while maintaining a low cost. This process… is truly fast and inexpensive,” said Tawfick.

The method begins with pouring dicyclopentadiene (DCPD) resin into an ice-cooled glass container. A center point is heated to 70°C, triggering a reaction that spreads outward at 1 mm/s—100 times faster than typical desktop 3D printers. This heat-driven solidification process, called frontal ring-opening metathesis polymerization (FROMP), requires minimal energy to form poly-dicyclopentadiene (p-DCPD).

As the solid structure expands, researchers manipulate its shape by pulling it from the resin—like dipping an apple in caramel. This liquid-to-solid transformation only occurs beneath the surface, allowing the object to be lifted, dipped, or spun to create different forms. To make a wavy edge, for instance, the resin is lifted slightly and held still before repeating.

Inspired by tree growth, Tawfick studied morphogenesis—the biological process that shapes organisms—after reading On Growth and Form by D’Arcy Wentworth Thompson. The team used growth printing to create a pinecone, a raspberry, a squash, and even a kiwi bird, adjusting timing to sculpt detailed features.

Philippe Geubelle, Illinois aerospace professor, noted: “The speed and energy efficiency of the growth-printing process make this process particularly attractive.” However, Tawfick acknowledged its limitations: complex shapes like a banana or a thorn are challenging. “Similarly, our process cannot make a perfect cube. It’s an interesting mirror of nature.”

Tawfick envisions this “simple and highly marketable” method being used for large polymer products like wind turbine blades. The US Department of Energy funded the project.