Hybrid Injection–Volumetric Additive Manufacturing for Rapid Fabrication of Low-Viscosity Multi-Material and Composite Structures

Hybrid Injection–Volumetric Additive Manufacturing for Rapid Fabrication of Low-Viscosity Multi-Material and Composite Structures | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Hybrid Injection–Volumetric Additive Manufacturing for Rapid Fabrication of Low-Viscosity Multi-Material and Composite Structures Omid Kordi, Amir Hossein Behravesh, Mohammad Mahdi Ghafari, Ali Kavian, and 3 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-8791467/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract In this study, a hybrid injection–volumetric additive manufacturing (HIVAM) approach is introduced to overcome key material limitations of volumetric additive manufacturing (VAM) and enable the ultrafast fabrication of composite structures and multi material parts. VAM has recently emerged as a rapid vat photopolymerization technique that addresses several key limitations of conventional additive manufacturing methods, including low printing speed, poor surface quality, the need for support structures, and anisotropic mechanical properties. Despite these advantages, VAM is currently restricted to highly transparent resins, and the use of opaque formulations or resin systems containing light-scattering fillers, as well as low-viscosity materials that are essential for composite and multi-material fabrication, remains extremely challenging. The proposed HIVAM approach integrates directional volumetric curing with synchronized in situ injection of a secondary material, enabling the fabrication of hollow, multi-material, and composite structures. Different injection algorithms and processing conditions are systematically investigated to identify stable fabrication windows and ensure dimensional integrity. The versatility of the method is demonstrated by combining materials with distinct physical states and matrices, including opaque resins, graphene oxide-reinforced resin, and injected shear-thickening fluids (STF). As proof of concept, composite parts containing up to 1.5 wt% graphene oxide and liquid-filled architectures exhibiting strain-rate-dependent mechanical behavior are successfully fabricated. The results show that HIVAM preserves the ultrafast nature of volumetric additive manufacturing while significantly expanding its material palette and architectural complexity. This work establishes a general platform for rapid multi-material and composite fabrication beyond the transparency and viscosity constraints of conventional volumetric processes. Volumetric additive manufacturing Hybrid injection–volumetric additive Manufacturing Composite fabrication Graphene oxide reinforcement Multi-material printing Liquid-filled architectures Full Text Additional Declarations No competing interests reported. Supplementary Files injection300speed1.mp4 Injection370Speed1.mp4 Injection370Speed15.mp4 Injection370Speed05.mp4 Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-8791467","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":596346024,"identity":"43aa1f22-7bea-4068-90f6-19c7f248a1bd","order_by":0,"name":"Omid Kordi","email":"","orcid":"","institution":"Tarbiat Modares University","correspondingAuthor":false,"prefix":"","firstName":"Omid","middleName":"","lastName":"Kordi","suffix":""},{"id":596346025,"identity":"320ef84b-2584-409a-97a6-dbe6cd62e38c","order_by":1,"name":"Amir Hossein Behravesh","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAA0ElEQVRIiWNgGAWjYBACNgbGBmbGBhsgMwEmxtiAVws/REsaCVokgdJALYeRtRAABtcOt30u3HE+mp89+dmHD38Y5PkbmNs+4NVyO7F59swzt3Nn9jwznjmzjcFwxgHG5hmEtDDztt3O3XAjwZiZt4GBcQMDYzNeh9lDtJwDakn/zPznD4M9QS1QWw4AteQYMwPDPJFILWeSgX55U8zY2yaRPOMwQS3pj5l5d9jl9rOnb2b48cfGtr+9/TFeLehAAhhNJGkYBaNgFIyCUYANAACZbUvdMW6wOgAAAABJRU5ErkJggg==","orcid":"","institution":"Tarbiat Modares University","correspondingAuthor":true,"prefix":"","firstName":"Amir","middleName":"Hossein","lastName":"Behravesh","suffix":""},{"id":596346027,"identity":"3743614a-0e2f-4ae4-840e-d15e40548d10","order_by":2,"name":"Mohammad Mahdi Ghafari","email":"","orcid":"","institution":"Tarbiat Modares University","correspondingAuthor":false,"prefix":"","firstName":"Mohammad","middleName":"Mahdi","lastName":"Ghafari","suffix":""},{"id":596346029,"identity":"84aa4df1-718a-4056-a7e4-6eb68cd4f028","order_by":3,"name":"Ali Kavian","email":"","orcid":"","institution":"Tarbiat Modares University","correspondingAuthor":false,"prefix":"","firstName":"Ali","middleName":"","lastName":"Kavian","suffix":""},{"id":596346030,"identity":"510d9b5e-678a-4a6d-b00b-96ca679de76f","order_by":4,"name":"Ahmad Reza Tahmasebi","email":"","orcid":"","institution":"Tarbiat Modares University","correspondingAuthor":false,"prefix":"","firstName":"Ahmad","middleName":"Reza","lastName":"Tahmasebi","suffix":""},{"id":596346034,"identity":"026dfd82-71c0-4608-931b-7504466ee9c4","order_by":5,"name":"Amir Ali Milani","email":"","orcid":"","institution":"Tarbiat Modares University","correspondingAuthor":false,"prefix":"","firstName":"Amir","middleName":"Ali","lastName":"Milani","suffix":""},{"id":596346036,"identity":"f4cadb6f-8277-4afb-a06a-81efc848573e","order_by":6,"name":"Ghaus Rizvi","email":"","orcid":"","institution":"Ontario Tech University","correspondingAuthor":false,"prefix":"","firstName":"Ghaus","middleName":"","lastName":"Rizvi","suffix":""}],"badges":[],"createdAt":"2026-02-05 02:53:39","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-8791467/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-8791467/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":104398621,"identity":"c2e58c61-94d9-436f-89a8-abc8086e9bfe","added_by":"auto","created_at":"2026-03-11 12:03:07","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":2429730,"visible":true,"origin":"","legend":"","description":"","filename":"HybridInjectionVolumetricAdditiveManufacturingAnonymous.pdf","url":"https://assets-eu.researchsquare.com/files/rs-8791467/v1_covered_3ffe0a8b-4da6-4d1f-ab14-ab5f3ed2bd46.pdf"},{"id":103532647,"identity":"9132e30a-b9b6-40eb-8779-227731c8ef6f","added_by":"auto","created_at":"2026-02-26 17:32:09","extension":"mp4","order_by":0,"title":"","display":"","copyAsset":false,"role":"supplement","size":9873831,"visible":true,"origin":"","legend":"","description":"","filename":"injection300speed1.mp4","url":"https://assets-eu.researchsquare.com/files/rs-8791467/v1/b3431c611c7403da71b190c6.mp4"},{"id":103532648,"identity":"037fd1ee-2d29-4aa6-804d-76ab1c570b10","added_by":"auto","created_at":"2026-02-26 17:32:09","extension":"mp4","order_by":1,"title":"","display":"","copyAsset":false,"role":"supplement","size":8227990,"visible":true,"origin":"","legend":"","description":"","filename":"Injection370Speed1.mp4","url":"https://assets-eu.researchsquare.com/files/rs-8791467/v1/3cf0b482d1578e231bee0815.mp4"},{"id":103532649,"identity":"a15709ec-05cd-4959-9cea-844ba2cb5e17","added_by":"auto","created_at":"2026-02-26 17:32:09","extension":"mp4","order_by":2,"title":"","display":"","copyAsset":false,"role":"supplement","size":10883069,"visible":true,"origin":"","legend":"","description":"","filename":"Injection370Speed15.mp4","url":"https://assets-eu.researchsquare.com/files/rs-8791467/v1/4bad8336ce6a7cde45766dca.mp4"},{"id":103532650,"identity":"22d7c413-7909-479b-a975-c18ac5bdcf09","added_by":"auto","created_at":"2026-02-26 17:32:09","extension":"mp4","order_by":3,"title":"","display":"","copyAsset":false,"role":"supplement","size":8816330,"visible":true,"origin":"","legend":"","description":"","filename":"Injection370Speed05.mp4","url":"https://assets-eu.researchsquare.com/files/rs-8791467/v1/f0b53172410bd96b2f7339d3.mp4"}],"financialInterests":"No competing interests reported.","formattedTitle":"Hybrid Injection–Volumetric Additive Manufacturing for Rapid Fabrication of Low-Viscosity Multi-Material and Composite Structures","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"Volumetric additive manufacturing, Hybrid injection–volumetric additive Manufacturing, Composite fabrication, Graphene oxide reinforcement, Multi-material printing, Liquid-filled architectures","lastPublishedDoi":"10.21203/rs.3.rs-8791467/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-8791467/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eIn this study, a hybrid injection\u0026ndash;volumetric additive manufacturing (HIVAM) approach is introduced to overcome key material limitations of volumetric additive manufacturing (VAM) and enable the ultrafast fabrication of composite structures and multi material parts. VAM has recently emerged as a rapid vat photopolymerization technique that addresses several key limitations of conventional additive manufacturing methods, including low printing speed, poor surface quality, the need for support structures, and anisotropic mechanical properties. Despite these advantages, VAM is currently restricted to highly transparent resins, and the use of opaque formulations or resin systems containing light-scattering fillers, as well as low-viscosity materials that are essential for composite and multi-material fabrication, remains extremely challenging. The proposed HIVAM approach integrates directional volumetric curing with synchronized in situ injection of a secondary material, enabling the fabrication of hollow, multi-material, and composite structures. Different injection algorithms and processing conditions are systematically investigated to identify stable fabrication windows and ensure dimensional integrity. The versatility of the method is demonstrated by combining materials with distinct physical states and matrices, including opaque resins, graphene oxide-reinforced resin, and injected shear-thickening fluids (STF). As proof of concept, composite parts containing up to 1.5 wt% graphene oxide and liquid-filled architectures exhibiting strain-rate-dependent mechanical behavior are successfully fabricated. The results show that HIVAM preserves the ultrafast nature of volumetric additive manufacturing while significantly expanding its material palette and architectural complexity. This work establishes a general platform for rapid multi-material and composite fabrication beyond the transparency and viscosity constraints of conventional volumetric processes.\u003c/p\u003e","manuscriptTitle":"Hybrid Injection–Volumetric Additive Manufacturing for Rapid Fabrication of Low-Viscosity Multi-Material and Composite Structures","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2026-02-26 17:32:04","doi":"10.21203/rs.3.rs-8791467/v1","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"02e1d1e8-3cf1-4110-b182-25118784d22f","owner":[],"postedDate":"February 26th, 2026","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"posted","subjectAreas":[],"tags":[],"updatedAt":"2026-04-22T16:40:30+00:00","versionOfRecord":[],"versionCreatedAt":"2026-02-26 17:32:04","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-8791467","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-8791467","identity":"rs-8791467","version":["v1"]},"buildId":"XKTyCvWXoU3ODBz1xrDgd","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}