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. 2026 Jul 28. Online ahead of print. doi: 10.1039/d6mh00947f

Table 2. Comparison of vat photopolymerization and extrusion printing techniques for 3D printing hydrogel actuators.

Technique Ink requirements Resolution Advantages Disadvantages
Vat photopolymerization graphic file with name d6mh00947f-u1.jpg • Photocurable resin124 • Lateral: 5–50 µm, dependent on laser spot size120,125 • High resolution – enables smaller feature sizes • Anisotropy may occur within layers due to curing gradient120
• Viscosity: <4 Pa s120 • Vertical: dependent on light penetration depth125 • Smooth surface finish • Difficult to print multiple inks120,124
• Fabrication rate: ∼105 mm3 h−1 128 • Additives may increase viscosity
graphic file with name d6mh00947f-t1.jpg • Large amounts of precursor solution needed (∼500 mL) and most remains unused129
graphic file with name d6mh00947f-u2.jpg • Photocurable resin124 • Lateral: 5–50 µm, dependent on projector pixel size120,125,130 • Faster printing speed than SLA120,125 • Lower resolution compared to SLA
• Viscosity: <4 Pa s120 • Vertical: dependent on light penetration depth125 • Typically less affected by oxygen inhibition than SLA125 • Difficult to print multiple inks120,124
• Fabrication Rate: ∼106 mm3 h−1 128 • Additives may increase viscosity
graphic file with name d6mh00947f-t2.jpg • Large amounts of precursor solution needed (∼500 mL) and most remains unused129
Extrusion 3D printing graphic file with name d6mh00947f-u3.jpg • Viscoelastic • Lateral: 1 – 150 µm, dependent on nozzle diameter and printing speed93,120,124 • Material versatility124 • Slower printing speeds and lower resolution compared to SLA and DLP
• Shear thinning122 • Vertical: dependent on ink yield stress and capillary forces131 • Easy to co-print multiple inks • Bubbles trapped between layers122
• Viscosity: 0.1–1000 Pa s96 • Fabrication Rate: ∼103–104 mm3 h−1 132 • Anisotropic alignment of fillers • Difficult to print overhangs122
• Storage modulus (G′): 104–105 Pa122 • Time ∝ (print speed) × (nozzle diameter)2 • Requires less ink than SLA and DLP129 • Unpolymerized structures may collapse under the weight of subsequent layers124
• Yield point (G′ = G″): 500–2500 Pa122 • Nozzle clogging due to viscous inks or fillers133
• Shape fidelity: dependent on tan δ (G′ > 1)93