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Additive manufacturing, such as 3D printing, offers unparalleledopportunities for rapid prototyping of complex three-dimensional objects, buttypically requires simultaneous building of solid supports to minimizedeformation and ensure contact with the printing surface. Here, wetheoretically and experimentally investigate the concept of material extrusionon an "air bed", a judiciously engineered acoustic field that supports thematerial by contactless radiation force. We study the dynamics of polylacticacid filament (PLA), a commonly used material in 3D printing, as it interactswith the acoustic potential during extrusion. We develop numerical models todetermine optimal transducer arrangements and printing conditions, and we buildand demonstrate a concept prototype that integrates a commercial 3D printer andopen-source control code. Our results point towards alternative, contactlesssupport mechanisms with potential benefits such as fewer surface defects, lessmaterial waste, lower cost, and reduced manufacturing time. These featurescould become crucial as additive manufacturing continues to evolve into afoundational tool in engineering and beyond.

3D Printing via material extrusion on an acoustic air bed