By positioning the sound source closer to the surface, researchers achieve enhanced resolution and repeatability in microscale 3D printing on deformable substrates.
Researchers at Concordia University have developed a new 3D-printing technique known as proximal sound printing that uses focused ultrasound waves to fabricate microscale structures directly onto soft polymers such as silicone. Building on earlier advances in direct sound printing, the refined method is engineered to deliver greater precision and control in the production of miniature components for advanced technological applications.
The approach is positioned to support rapid prototyping across sectors that depend on compact and flexible systems. Potential applications include medical diagnostic devices, environmental monitoring platforms, wearable electronics and soft robotic components. By improving resolution, lowering power requirements and enhancing process stability, the technique provides a more controlled and adaptable pathway for manufacturing next-generation microscale devices.
Compared with previous ultrasound-based printing methods, proximal sound printing achieves significantly finer feature resolution. By positioning the sound source closer to the printing surface, the researchers gained tighter spatial control over polymer solidification. This enabled the fabrication of features up to ten times smaller than earlier techniques, while also improving repeatability and reducing energy consumption. The method is compatible with materials commonly used in microfluidics, lab-on-a-chip systems and soft electronics, which are often challenging to process using conventional heat- or light-driven fabrication approaches. This material compatibility broadens design flexibility for microscale systems built on soft, deformable substrates.
At its core, the process directs focused ultrasound to initiate localized chemical reactions that cure liquid polymers exactly where needed. This precise activation allows complex geometries, including microfluidic channels, flexible sensors and multi-material structures, to be produced within a single manufacturing workflow. The enhanced control addresses limitations observed in earlier sound-printing approaches and supports more consistent fabrication of intricate microscale designs.
