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Embedded 3D printing beyond formability: process-window design; interfacial fidelity and application reliability
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DOI：10.3389/fmats.2026.1872977.png)
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Abstract
En 中文
Embedded 3D printing (EMB-3DP) has changed the way soft; flowable and functional materials are shaped in three-dimensional space. By depositing inks inside a supporting medium rather than in air; this technique reduces gravitational collapse; allows freeform toolpaths and enables the fabrication of structures that are difficult to obtain by conventional additive manufacturing. However; the further development of embedded 3D printing should not be judged only by whether complex shapes can be printed. For practical use; the more important question is whether the printed structure can retain its geometry; interface quality and function during printing; curing; support removal and long-term service. This review discusses embedded 3D printing from the perspective of process-window design and application reliability. Particular attention is given to rheological matching; interfacial instability; structural suspension; sacrificial-material removal; and the functional durability of printed devices. Flexible electronics; vascularized tissues; soft robots and microfluidic systems are used as representative examples to show that printing fidelity and device reliability are closely linked. Finally; challenges and future directions are proposed; including quantitative printability maps; recyclable support systems; interface-aware multi-material design and closed-loop process control.
Keywords:
interfacial stability
embedded 3D printing
functional reliability
printability
process window
structural fidelity
Journal
F
IF:
2.9
Papers:
296
Citations:
0
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