Researchers develop innovative DLP 3D printing technique that turns overcuring into an advantage for creating gecko-inspired soft grippers.
Researchers from Hanyang University have developed a pioneering DLP 3D printing method that transforms a common printing defect into a beneficial feature, creating gecko-inspired soft grippers capable of handling delicate objects.
The technique, published in Microsystems & Nanoengineering this month, strategically uses overcuring—typically considered a flaw in 3D printing—to produce anisotropic microstructures that mimic the adhesive properties of gecko feet.
“By precisely controlling exposure time, light intensity, and layer geometry, we’ve manipulated UV penetration to create asymmetrical structures without complex lithography,” explained lead researchers Sooheon Kim and Hongyun So.
The soft grippers produced through this method demonstrated impressive capabilities, reliably lifting objects up to 165 grams, including 4-inch and 8-inch silicon wafers and heavy glass dishes, using minimal mechanical input.
Tests comparing standard 3D printed structures to the overcured designs showed an 18.7% reduction in maximum stress under loading conditions, indicating improved structural durability for repeated use.
The grippers also demonstrated remarkable resilience in practical environments. Following purposeful dust contamination, cleaning with isopropyl alcohol restored 96.78% of the original adhesive strength, confirming renewed usability possibilities.
Although the primary focus concentrates on wafer handling in electronics manufacturing, the technique applies more broadly to microfluidics, filtration, and biomedical devices.
This joins an increasing trend of biomimetic design in additive manufacturing, in which researchers design using materials in ways that emulate natural systems. Other known cases include 3D-printed cuttlefish bone structures, butterfly wings, and vascular models.
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The Hanyang University team’s approach pushes biomimicry beyond visual resemblance into functional emulation, offering new possibilities for soft robotics and precision handling applications where traditional grippers might cause damage.
