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Curl distortion has been a persistent challenge for vat photopolymerization‐based printing technology such as digital light processing (DLP), leading to structural deformation and print failures. This study presents a new approach to mitigate curling distortion and heat effects during DLP printing by dividing the printing layer image into sequential subimages, using a breadth‐first search algorithm. The progressive curing process, resembling a ripple pattern, results in a significant improvement in printing accuracy. The deviation is reduced tenfold when the layer image is divided into subimages with 10 pixels for a 32 mm diameter disc. Additionally, subdivision strategy helps to reduce the heat effect during photopolymerization, as monitored in situ by a long‐wave infrared camera. The successful reduction of residual stress using the subdivision strategy results in a 75% improvement in the mechanical performance of the printed products. The simple adoption of subdivision strategy in practical 3D printing applications is also demonstrated. For solid 3D printing structures, introducing intervals within the solid printing layers—such as using a grid structure instead of a fully solid one, can help to reduce curling and heat effects, thereby improving 3D printing accuracy. [ABSTRACT FROM AUTHOR] more...

The flexibility and controllability of 3D printing technologies have made them popular for creating integrated wearable sensors. However, producing sensors with 3D anisotropic response is still difficult with current printing materials and techniques. To address this challenge, digital light process (DLP) printing technology with blading function to fabricate 3D anisotropic pressure and strain sensors is used. By applying blading‐induced shearing force, nanoalignment of carbon nanotubes (CNTs) in each layer is achieved, while the continuous liquid interface production of the DLP printing process facilitates good electrical communication between adjacent microlayers. The constructed 3D sensor displays high tensile and pressure responses up to 40 MPa and the ability to detect pressure changes in all directions. Additionally, the resistance anisotropy ratio range is adjustable. Finite‐element method (FEM) simulation shows that the relative change in resistance has an anisotropic distribution that aligns well with experimental results. The work would offer a new way to create 3D anisotropic pressure/strain sensors for advanced flexible and stretchable sensing applications. [ABSTRACT FROM AUTHOR] more...