How Did a 3D Printing Error Turn Into Gecko-Inspired Anisotropic Structures?

What if a 3D printing defect could become the key to developing a new technology? This is the proposal of a group of researchers at Hanyang University in South Korea, who took advantage of overcuring to create adhesive surfaces inspired by geckos. Using the DLP process, they have managed to replicate anisotropic structures similar to those of the legs of these reptiles, known for their ability to adhere to and detach from surfaces.

The hope is that these structures could be useful for applications like soft robotics, biomedical devices and systems that serve to manipulate objects. The study was published in the journal Mirosystems & Nanoengineering and involved several departments at the Korean university.

Explanation of the process for obtaining and testing anisotropic structures (photo credits: Kim, S., Kim, J., Seo, S. et al.).

For those who don’t know, the DLP 3D printing process involves selectively solidifying resins using light. However, one of its main challenges with it is overcuring, which occurs when the light reaches further than expected and hardens the part in unwanted areas. Normally, this is considered a defect as the accuracy of the structure is altered.