3D printing using conventional stereolithography is challenging because the polymerized layers adhere to the solid constraining interface. The mechanical separation forces lead to poor process reliability and limit the geometrical design space of the printed parts. Here, these challenges are overcome by utilizing a static inert immiscible liquid below the resin as the constraining interface. We elucidate the mechanisms that enable the static liquid to mitigate stiction in both discrete layer-by-layer and continuous layerless growth modes. The inert liquid functions as a dewetting interface during the discrete growth and as a carrier of oxygen to inhibit polymerization during the continuous growth. This method enables a wide range of process conditions, such as exposure and resin properties, which facilitates micrometer scale resolutions and dimensional accuracies above 95%. We demonstrate multi-scale microstructures with feature sizes ranging from 16 μm to thousands of micrometers and functional devices with aspect ratios greater than 50:1 without using sacrificial supports. This process can enable additive 3D microfabrication of functional devices for a variety of applications.

由于聚合层粘附在固体约束界面上，因此使用常规立体光刻技术进行3D打印具有挑战性。机械分离力导致较差的过程可靠性，并限制了印刷零件的几何设计空间。在这里，通过利用树脂下方的惰性惰性不溶混液体作为约束界面，可以克服这些挑战。我们阐明了使静态液体能够减轻离散的逐层和连续无层生长模式下的粘滞的机制。惰性液体在不连续生长期间充当去湿界面，并在连续生长期间充当氧气的载体以抑制聚合。这种方法可实现各种工艺条件，例如曝光和树脂性能，有助于实现微米级的分辨率和95％以上的尺寸精度。我们演示了特征尺寸从16μm到数千微米的多尺度微结构，以及不使用牺牲支撑的长宽比大于50：1的功能设备。这个过程可以使功能性设备的3D加法微制造成为可能。