1 Optical Bio Microsystems Laboratory, Micro-Nano-Bio Integration Center, Department of Mechanical, Industrial and Aerospace Engineering, Concordia University, Montreal, Canada.
2 Advanced Manufacturing Laboratory, Department of Mechanical and Aerospace Engineering, University of California, Davis, Davis, California, USA.

Direct sound printing (DSP) is a recent development in additive manufacturing processes using sound waves, in which cavitation bubbles created by a focused ultrasound field polymerize the liquid resin via the sonochemistry route. This article presents the first attempt to create functional parts, such as cantilevers and millifluidic systems in polydimethylsiloxane using DSP. The numerical simulations of acoustic propagation in the DSP and possible high-pressure zones in different media during the process are presented. The printed parts were characterized, and porosity analyses of the printed parts and postprocessing of the ultrasound source motion were performed.