Printing Three-Dimensional Electrical Traces in Additive Manufactured Parts for Injection of Low Melting Temperature Metals

2015 ◽  
Vol 7 (2) ◽  
Author(s):  
John P. Swensen ◽  
Lael U. Odhner ◽  
Brandon Araki ◽  
Aaron M. Dollar
Keyword(s):  
Fused Deposition Modeling ◽  
Printed Circuit Board ◽  
Three Dimensional ◽  
Circuit Board ◽  
Electronic Components ◽  
Fused Deposition ◽  
Liquid Metal Alloy ◽  
Deposition Modeling ◽  
3D Printed ◽  
Electrical Components

While techniques exist for the rapid prototyping of mechanical and electrical components separately, this paper describes a method where commercial additive manufacturing (AM) techniques can be used to concurrently construct the mechanical structure and electronic circuits in a robotic or mechatronic system. The technique involves printing hollow channels within 3D printed parts that are then filled with a low melting point liquid metal alloy that solidifies to form electrical traces. This method is compatible with most conventional fused deposition modeling and stereolithography (SLA) machines and requires no modification to an existing printer, though the technique could easily be incorporated into multimaterial machines. Three primary considerations are explored using a commercial fused deposition manufacturing (FDM) process as a testbed: material and manufacturing process parameters, simplified injection fluid mechanics, and automatic part generation using standard printed circuit board (PCB) software tools. Example parts demonstrate the ability to embed circuits into a 3D printed structure and populate the surface with discrete electronic components.

Development of a Fused Deposition Modeling System for Low Melting Temperature Metal Alloys

2013 ◽  
Vol 135 (1) ◽  
Author(s):  
Jorge Mireles ◽  
Ho-Chan Kim ◽  
In Hwan Lee ◽  
David Espalin ◽  
Francisco Medina ◽  
...  
Keyword(s):  
Melting Temperature ◽  
Fused Deposition Modeling ◽  
Printed Circuit Board ◽  
Three Dimensional ◽  
Single Layer ◽  
Metal Alloys ◽  
Circuit Board ◽  
Fused Deposition ◽  
Extrusion Head ◽  
Deposition Modeling

This research focused on extending the applications of fused deposition modeling (FDM) by extrusion and deposition of low melting temperature metal alloys to create three-dimensional metal structures and single-layer contacts which may prove useful for electronic interconnects. Six commercially available low melting temperature solder alloys (Bi36Pb32Sn31Ag1, Bi58Sn42, Sn63Pb37, Sn50Pb50, Sn60Bi40, Sn96.5Ag3.5) were tested for the creation of a fused deposition modeling for metals (FDMm) system with special attention given to Sn–Bi solders. An existing FDM 3000 was used and two alloys were successfully extruded through the system's extrusion head. Deposition was achieved through specific modifications to system toolpath commands and a comparison of solders with eutectic and non-eutectic compositions is discussed. The modifications demonstrate the ability to extrude simple single-layer solder lines with varying thicknesses, including sharp 90 deg angles and smooth curved lines and showing the possibility of using this system for printed circuit board applications in which various connections need to be processed. Deposition parameters altered for extrusion and the deposition results of low melting temperature metal alloys are introduced.

Development of three-dimensional printing filaments based on poly(lactic acid)/hydroxyapatite composites with potential for tissue engineering

2021 ◽  
pp. 002199832098856
Author(s):  
Marcela Piassi Bernardo ◽  
Bruna Cristina Rodrigues da Silva ◽  
Luiz Henrique Capparelli Mattoso
Keyword(s):  
Tissue Engineering ◽  
Lactic Acid ◽  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Poly Lactic Acid ◽  
Scanning Calorimetry ◽  
Three Dimensional Printing ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
3D Printed

Injured bone tissues can be healed with scaffolds, which could be manufactured using the fused deposition modeling (FDM) strategy. Poly(lactic acid) (PLA) is one of the most biocompatible polymers suitable for FDM, while hydroxyapatite (HA) could improve the bioactivity of scaffold due to its chemical composition. Therefore, the combination of PLA/HA can create composite filaments adequate for FDM and with high osteoconductive and osteointegration potentials. In this work, we proposed a different approache to improve the potential bioactivity of 3D printed scaffolds for bone tissue engineering by increasing the HA loading (20-30%) in the PLA composite filaments. Two routes were investigated regarding the use of solvents in the filament production. To assess the suitability of the FDM-3D printing process, and the influence of the HA content on the polymer matrix, thermogravimetric analysis (TGA), differential scanning calorimetry (DSC) and scanning electron microscopy (SEM) were performed. The HA phase content of the composite filaments agreed with the initial composite proportions. The wettability of the 3D printed scaffolds was also increased. It was shown a greener route for obtaining composite filaments that generate scaffolds with properties similar to those obtained by the solvent casting, with high HA content and great potential to be used as a bone graft.

scholarly journals 3D-Printed Soft Structure of Polyurethane and Magnetorheological Fluid: A Proof-of-Concept Investigation of its Stiffness Tunability

Micromachines ◽  
2019 ◽  
Vol 10 (10) ◽  
pp. 655 ◽  
Author(s):  
Seong-Woo Hong ◽  
Ji-Young Yoon ◽  
Seong-Hwan Kim ◽  
Sun-Kon Lee ◽  
Yong-Rae Kim ◽  
...  
Keyword(s):  
Fused Deposition Modeling ◽  
Permanent Magnets ◽  
Thermoplastic Polyurethane ◽  
Three Dimensional ◽  
Magnetorheological Fluid ◽  
Three Dimensional Printing ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
3D Printed ◽  
Dimensional Printing

In this study, a soft structure with its stiffness tunable by an external field is proposed. The proposed soft beam structure consists of a skin structure with channels filled with a magnetorheological fluid (MRF). Two specimens of the soft structure are fabricated by three-dimensional printing and fused deposition modeling. In the fabrication, a nozzle is used to obtain channels in the skin of the thermoplastic polyurethane, while another nozzle is used to fill MRF in the channels. The specimens are tested by using a universal tensile machine to evaluate the relationships between the load and deflection under two different conditions, without and with permanent magnets. It is empirically shown that the stiffness of the proposed soft structure can be altered by activating the magnetic field.

scholarly journals Typography-Like 3D-Printed Templates for the Lithography-Free Fabrication of Microfluidic Chips

2019 ◽  
Vol 25 (1) ◽  
pp. 82-87
Author(s):  
Wenqiong Su ◽  
Yulong Li ◽  
Lulu Zhang ◽  
Jiahui Sun ◽  
Shuopeng Liu ◽  
...  
Keyword(s):  
Processing Time ◽  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Cost Effective ◽  
Microfluidic Channels ◽  
3D Printer ◽  
Microfluidic Chips ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
3D Printed

Typography-like templates for polydimethylsiloxane (PDMS) microfluidic chips using a fused deposition modeling (FDM) three-dimensional (3D) printer are presented. This rapid and fast proposed scheme did not require complicated photolithographic fabrication facilities and could deliver resolutions of ~100 μm. Polylactic acid (PLA) was adopted as the material to generate the 3D-printed units, which were then carefully assembled on a glass substrate using a heat-melt-curd strategy. This craft of bonding offers a cost-effective way to design and modify the templates of microfluidic channels, thus reducing the processing time of microfluidic chips. Finally, a flexible microfluidic chip to be employed for cell-based drug screening was developed based on the modularized 3D-printed templates. The lithography-free, typography-like, 3D-printed templates create a modularized fabrication process and promote the prevalence of integrated microfluidic systems with minimal requirements and improved efficiency.

3D Printed Electrochemical Sensors

2021 ◽  
Vol 14 (1) ◽  
Author(s):  
Aya Abdalla ◽  
Bhavik Anil Patel
Keyword(s):  
Fused Deposition Modeling ◽  
Electrochemical Sensors ◽  
Three Dimensional ◽  
Annual Review ◽  
Publication Date ◽  
Fused Deposition ◽  
Novel Approach ◽  
Deposition Modeling ◽  
3D Printed ◽  
Analytical Tools

Three-dimensional (3D) printing has recently emerged as a novel approach in the development of electrochemical sensors. This approach to fabrication has provided a tremendous opportunity to make complex geometries of electrodes at high precision. The most widely used approach for fabrication is fused deposition modeling; however, other approaches facilitate making smaller geometries or expanding the range of materials that can be printed. The generation of complete analytical devices, such as electrochemical flow cells, provides an example of the array of analytical tools that can be developed. This review highlights the fabrication, design, preparation, and applications of 3D printed electrochemical sensors. Such developments have begun to highlight the vast potential that 3D printed electrochemical sensors can have compared to other strategies in sensor development. Expected final online publication date for the Annual Review of Analytical Chemistry, Volume 14 is August 2021. Please see http://www.annualreviews.org/page/journal/pubdates for revised estimates.

scholarly journals Fabrication of Drug-Eluting Nano-Hydroxylapatite Filled Polycaprolactone Nanocomposites Using Solution-Extrusion 3D Printing Technique

Polymers ◽  
2021 ◽  
Vol 13 (3) ◽  
pp. 318 ◽  
Author(s):  
Pang-Yun Chou ◽  
Ying-Chao Chou ◽  
Yu-Hsuan Lai ◽  
Yu-Ting Lin ◽  
Chia-Jung Lu ◽  
...  
Keyword(s):  
3D Printing ◽  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Fused Deposition ◽  
Drug Eluting ◽  
Deposition Modeling ◽  
3D Printed ◽  
Good Biocompatibility ◽  
3D Printing Technique ◽  
Moving Speed

Polycaprolactone/nano-hydroxylapatite (PCL/nHA) nanocomposites have found use in tissue engineering and drug delivery owing to their good biocompatibility with these types of applications in addition to their mechanical characteristics. Three-dimensional (3D) printing of PCL/nHA nanocomposites persists as a defiance mostly because of the lack of commercial filaments for the conventional fused deposition modeling (FDM) method. In addition, as the composites are prepared using FDM for the purpose of delivering pharmaceuticals, thermal energy can destroy the embedded drugs and biomolecules. In this report, we investigated 3D printing of PCL/nHA using a lab-developed solution-extrusion printer, which consists of an extrusion feeder, a syringe with a dispensing nozzle, a collection table, and a command port. The effects of distinct printing variables on the mechanical properties of nanocomposites were investigated. Drug-eluting nanocomposite screws were also prepared using solution-extrusion 3D printing. The empirical outcomes suggest that the tensile properties of the 3D-printed PCL/nHA nanocomposites increased with the PCL/nHA-to-dichloromethane (DCM) ratio, fill density, and print orientation but decreased with an increase in the moving speed of the dispensing tip. Furthermore, printed drug-eluting PCL/nHA screws eluted high levels of antimicrobial vancomycin and ceftazidime over a 14-day period. Solution-extrusion 3D printing demonstrated excellent capabilities for fabricating drug-loaded implants for various medical applications.

scholarly journals Three-dimensional printing of anatomically accurate, patient specific intracranial aneurysm models

2015 ◽  
Vol 8 (5) ◽  
pp. 517-520 ◽  
Author(s):  
Jeff R Anderson ◽  
Walker L Thompson ◽  
Abdulaziz K Alkattan ◽  
Orlando Diaz ◽  
Richard Klucznik ◽  
...  
Keyword(s):  
Fused Deposition Modeling ◽  
Statistical Significance ◽  
Three Dimensional ◽  
Cerebral Aneurysms ◽  
Patient Specific ◽  
Parent Artery ◽  
Significant Group ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
3D Printed

ObjectiveTo develop and validate a method for creating realistic, patient specific replicas of cerebral aneurysms by means of fused deposition modeling.MethodsThe luminal boundaries of 10 cerebral aneurysms, together with adjacent proximal and distal sections of the parent artery, were segmented based on DSA images, and corresponding virtual three-dimensional (3D) surface reconstructions were created. From these, polylactic acid and MakerBot Flexible Filament replicas of each aneurysm were created by means of fused deposition modeling. The accuracy of the replicas was assessed by quantifying statistical significance in the variations of their inner dimensions relative to 3D DSA images. Feasibility for using these replicas as flow phantoms in combination with phase contrast MRI was demonstrated.Results3D printed aneurysm models were created for all 10 subjects. Good agreement was seen between the models and the source anatomy. Aneurysm diameter measurements of the printed models and source images correlated well (r=0.999; p<0.001), with no statistically significant group difference (p=0.4) or observed bias. The SDs of the measurements were 0.5 mm and 0.2 mm for source images and 3D models, respectively. 3D printed models could be imaged with flow via MRI.ConclusionsThe 3D printed aneurysm models presented were accurate and were able to be produced inhouse. These models can be used for previously cited applications, but their anatomical accuracy also enables their use as MRI flow phantoms for comparison with ongoing studies of computational fluid dynamics. Proof of principle imaging experiments confirm MRI flow phantom utility.

Mechanical and morphological investigations of 3D printed recycled ABS reinforced with bakelite–SiC–Al2O3

2019 ◽  
Vol 233 (17) ◽  
pp. 5933-5944 ◽  
Author(s):  
Rupinder Singh ◽  
Inderpreet Singh ◽  
Ranvijay Kumar
Keyword(s):  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Acrylonitrile Butadiene Styrene ◽  
Morphological Properties ◽  
Fused Deposition ◽  
Software Configuration ◽  
Twin Screw ◽  
Deposition Modeling ◽  
3D Printed ◽  
Commercial Applications

The utilization of thermosetting waste is a serious issue as it is not recycled commercially due to inherent molecular properties and high technology cost. This research details the study of the mechanical behavior and surface analysis with energy-dispersive X-ray spectroscopy and scanning electron microscope of three-dimensional printed parts of the waste thermosetting polymer, bakelite (BAK) as the reinforcement along with ceramic particles (SiC and Al2O3) in recycled thermoplastic acrylonitrile butadiene styrene matrix for sustainability. The process involves twin-screw extrusion for the preparation of filament, followed by 3D printing of functional prototypes on fused deposition modeling setup. The 3D printed parts prepared with fused deposition modeling were used for the testing of mechanical, thermal, and morphological properties. The results of the present study suggests that for commercial applications recycling of thermoplastic up to 10 wt% can be easily performed without a change in any hardware/ software configuration of the fused deposition modeling setup and the ceramic concentration in thermoplastic-thermosetting blends further led to better mechanical and surface properties.

scholarly journals Flexible 3D Printed Conductive Metamaterial Units for Electromagnetic Applications in Microwaves

Materials ◽  
2020 ◽  
Vol 13 (17) ◽  
pp. 3879
Author(s):  
Anna C. Tasolamprou ◽  
Despoina Mentzaki ◽  
Zacharias Viskadourakis ◽  
Eleftherios N. Economou ◽  
Maria Kafesaki ◽  
...  
Keyword(s):  
Fused Deposition Modeling ◽  
Low Cost ◽  
Three Dimensional ◽  
Dielectric Materials ◽  
Ring Resonators ◽  
Free Standing ◽  
Fused Deposition ◽  
Structural Details ◽  
Deposition Modeling ◽  
3D Printed

In this work we present a method for fabricating three dimensional, ultralight and flexible millimeter metamaterial units using a commercial household 3D printer. The method is low-cost, fast, eco-friendly and accessible. In particular, we use the Fused Deposition Modeling 3D printing technique and we fabricate flexible conductive Spilt Ring Resonators (SRRs) in a free-standing form. We characterized the samples experimentally through measurements of their spectral transmission, using standard rectangular microwave waveguides. Our findings show that the resonators produce well defined resonant electromagnetic features that depend on the structural details and the infiltrating dielectric materials, indicating that the thin, flexible and light 3D printed structures may be used as electromagnetic microwave components and electromagnetic fabrics for coating a variety of devices and infrastructure units, while adapting to different shapes and sizes.

scholarly journals Multi-Response Optimization of Tensile Creep Behavior of PLA 3D Printed Parts Using Categorical Response Surface Methodology

Polymers ◽  
2020 ◽  
Vol 12 (12) ◽  
pp. 2962
Author(s):  
Muhammad Waseem ◽  
Bashir Salah ◽  
Tufail Habib ◽  
Waqas Saleem ◽  
Muhammad Abas ◽  
...  
Keyword(s):  
Creep Rate ◽  
Creep Behavior ◽  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Rupture Time ◽  
Tensile Creep ◽  
Layer Height ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
3D Printed

Three-dimensional printed plastic products developed through fused deposition modeling (FDM) endure long-term loading in most of the applications. The tensile creep behavior of such products is one of the imperative benchmarks to ensure dimensional stability under cyclic and dynamic loads. This research dealt with the optimization of the tensile creep behavior of 3D printed parts produced through fused deposition modeling (FDM) using polylactic acid (PLA) material. The geometry of creep test specimens follows the American Society for Testing and Materials (ASTM D2990) standards. Three-dimensional printing is performed on an open-source MakerBot desktop 3D printer. The Response Surface Methodology (RSM) is employed to predict the creep rate and rupture time by undertaking the layer height, infill percentage, and infill pattern type (linear, hexagonal, and diamond) as input process parameters. A total of 39 experimental runs were planned by means of a categorical central composite design. The analysis of variance (ANOVA) results revealed that the most influencing factors for creep rate were layer height, infill percentage, and infill patterns, whereas, for rupture time, infill pattern was found significant. The optimized levels obtained for both responses for hexagonal pattern were 0.1 mm layer height and 100% infill percentage. Some verification tests were performed to evaluate the effectiveness of the adopted RSM technique. The implemented research is believed to be a comprehensive guide for the additive manufacturing users to determine the optimum process parameters of FDM which influence the product creep rate and rupture time.

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