Dissolvable Supports and Multi Material 3D Printing

In recent years, digital light processing also known as DLP 3D printing has developed steadily. Equipment and materials have become more affordable, and there is now a much wider selection of resins. However, some important limitations have remained. Each resin has a fixed function determined by its chemistry, so it has not been possible to combine materials with different properties in one continuous print. Supports have also been a challenge because they often leave surface marks and require time-consuming post processing.

Upside Parts - Dissolvable Supports and Multi Material 3D Printing

Researchers at the University of Texas at Austin have introduced a solution to both of these problems. Their recent study describes a resin system and a dual light printing process that can create both flexible and rigid areas in a single print. It also enables dissolvable supports. This approach allows multi material 3D printing that improves print quality, reduces labor, and makes more complex designs possible. The full study is available in Nature Materials and can be accessed here. 

How the Texas Researchers Achieved Multi Material 3D Printing

The research team created resins that respond differently depending on the wavelength of light. When illuminated with violet light, the resin cures into a rubber like material that can bend and stretch. When exposed to ultraviolet light, it becomes rigid and strong, more like an engineering plastic. This allows one print to contain areas that flex and others that hold firm, achieving true multi material 3D printing in a single build.

The same resin chemistry also makes it possible to create dissolvable supports. These supports can be removed in a safe solvent within minutes. For users of DLP technology, this is a practical improvement. It allows complex freestanding geometries such as chains, hooks, and moving joints to be printed without leaving surface scars from manual support removal.

In their proof of concept prints, the team created small hooks, chains, and a functional knee joint with flexible ligaments and rigid bones that moved smoothly. They also demonstrated a stretchable electronic device with a gold wire embedded in a strip that could bend without breaking the circuit.

This work was published in Nature Materials and more details are available in the official UT Austin release.

Why Dissolvable Supports Improve DLP Printing

Supports have long been a limitation of DLP 3D printing. While the process is precise and fast, supports must often be removed manually, which leaves marks on the surface and requires extra finishing. With this new process, dissolvable supports can be removed safely, leaving clean surfaces and reducing the time needed after printing.

At the same time, the ability to create both soft and rigid areas in one continuous print unlocks new design possibilities. It allows designers to mimic natural transitions between flexible and firm materials, such as cartilage and bone, within a single part. This capability was previously only available on more expensive systems like PolyJet.

Together, dissolvable supports and multi material 3D printing make DLP more practical for a wider range of designs.

Industry Insights on the Impact of This Research

This research shows how much DLP has advanced in a relatively short time. Equipment costs have decreased, resins have become more available, and the types of achievable parts have expanded. Until now, every resin served a single purpose, and it was not possible to combine different material properties in one continuous process.

The new approach from the University of Texas changes this. It combines flexible and rigid materials during a single print and also allows dissolvable supports to be removed without surface damage. It can be applied not only to medical devices and wearables but also to robotics, soft actuators, consumer products, and custom tools. If the cost remains affordable, this technology could support much wider use of multi material 3D printing in many industries.

Equally important, dissolvable supports remove a long standing workflow barrier for DLP users. Designers will be able to create interlocking mechanisms, complex lattices, or moving parts in one print without tedious post processing.

Practical Takeaways from the University of Texas Study 

For businesses, designers, and engineers, the key takeaway is that material development continues to expand the possibilities of DLP printing. This specific dual light resin system is not yet commercially available, but it shows a clear direction for the technology. It simplifies post processing, allows more complex designs, and makes DLP printing more practical for functional parts.

As more advanced resins reach the market, they will reduce labor and make it easier to create detailed and accurate parts on desktop and mid range DLP systems.

If you want to explore what current materials can already achieve, you can read about our SLA printing services, learn about standard resin printing materials, or see how ABS like resin printing improves strength and durability.

The University of Texas research shows how combining advanced resin chemistry with dual light printing can remove two of the biggest limitations of DLP 3D printing. By enabling dissolvable supports and allowing multi material 3D printing in one process, it improves both design freedom and workflow efficiency. As these new materials move closer to commercial availability, they will help bring DLP printing beyond prototypes and models into broader industrial and consumer use.

If you want to discuss how resin 3D printing can support your next project, contact us to find the best solution for your needs.