Rotational 3D printing technique with pixel compensation for enhanced dynamic performance

Projection-based 3D printing technique faces inherent limitations in edge fidelity due to optical pixilation, compromising the functional performance of fabricated devices. Here, we introduce a unique rotational 3D printing (R3DP) technique, a novel platform integrating synchronized axial rotation with dynamic layer-by-layer photopolymerization. Our method compensates for missing edge pixels through programmable angular displacement (ω), enabling the fabrication of structures with sub-voxel resolution and directionally optimized surfaces. Compared to static DLP printing, R3DP reduces surface roughness by >40% and eliminates jagged edges, translating to enhanced mechanical resilience—spring filaments exhibit strain hardening beyond 0.8 mm mm⁻¹ and tunable Young’s modulus (8–757 MPa) via ω-controlled layer alignment. Moreover, R3DP-fabricated spring channels achieve 56% higher capillary velocity than DLP counterparts by suppressing pixel-induced turbulence. For aerodynamic components, R3DP-printed propellers generate thrust comparable to commercial counterparts (15.2 ± 0.8 N vs. 16.5 ± 0.5 N at 20,000 rpm) while reducing acoustic emissions by 3–5 dB through laminar flow stabilization. Flight validation confirms stable UAV operation with 12% lower torque resistance, demonstrating R3DP’s viability for high-performance applications in mechanics, microfluidics, and aerospace.