Novel Fast Cure Silicone Inks for Single‐Step, Support‐Free 3D Printing of Tall, Overhanging, and High Aspect Ratio Structures

Abstract Silicone elastomers have a broad variety of applications, such as soft robotics, biomedical devices, and structural metamaterials. The extrusion‐based method known as direct ink write (DIW) has enabled the production of additively manufactured silicone structures. However, this method is limited to manufacturing mostly planar or pseudo‐3D structures. Due to the low self‐supporting capabilities of extruded strands for traditional silicone‐based “inks,” obtaining tall or overhanging structures, or structures comprised by thin walls is not feasible. Here, a novel Fast Cure silicone‐based ink is demonstrated that enables manufacturing of complex 3D structures. The Fast Cure ink is a two‐part mixture and silicone structures are produced by inline mixing and coextrusion of a part containing a catalyst (part A) and a part containing a crosslinker (part B). By the virtue of crosslinking, the extruded strands rapidly rigidize, increasing their self‐supportive capacity. Hence, structures can be obtained with superior shape retention and previously unobtainable parts are realized that are tall, with aspect ratios higher than 3, and have overhanging features, achieving inclination angles smaller than 35° with respect to the printing plane. These minimal sag parts are achieved without requiring extra curing or mechanisms, support structures, or suspension baths.