Shaping soft materials via digital light processing-based 3D printing: A review

Soft materials exhibiting unique nonlinear mechanical behavior with large deformation are ubiquitous in nature. In addition, there is a type of soft active materials (SAMs) that can undergo large mechanical deformation. In recent years, soft materials have been developed for impactful applications in aerospace, biomedical devices, and soft robots. However, the traditional manufacturing approaches greatly limit the functionality and performance of structures and devices made of soft materials. 3D printing as an emerging advanced manufacturing technology is considered as an ideal tool to manufacture soft materials. Compared with other 3D printing technologies, digital light processing (DLP)-based 3D printing fabricates 3D objects by localized photopolymerization, and is capable of fabricating 3D objects with highly complex geometries and high resolution. Recently, DLP-based 3D printing has demonstrated its excellent compatibility with a variety of soft materials, and is capable of manufacturing these soft materials into 3D structures and devices with complex geometries, high resolution and unique performance. This reviewer article presents a brief but timely introduction to the most recent advances in DLP-based 3D printing of soft materials.