Scalable submicrometer additive manufacturing

Science ◽  
2019 ◽  
Vol 366 (6461) ◽  
pp. 105-109 ◽  
Author(s):  
Sourabh K. Saha ◽  
Dien Wang ◽  
Vu H. Nguyen ◽  
Yina Chang ◽  
James S. Oakdale ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Design Space ◽  
Three Dimensional ◽  
Complex Structures ◽  
Layer By Layer ◽  
Promising Candidate ◽  
Single Digit ◽  
Cross Sectional ◽  
Two Photon ◽  
Nanoscale Features

High-throughput fabrication techniques for generating arbitrarily complex three-dimensional structures with nanoscale features are desirable across a broad range of applications. Two-photon lithography (TPL)–based submicrometer additive manufacturing is a promising candidate to fill this gap. However, the serial point-by-point writing scheme of TPL is too slow for many applications. Attempts at parallelization either do not have submicrometer resolution or cannot pattern complex structures. We overcome these difficulties by spatially and temporally focusing an ultrafast laser to implement a projection-based layer-by-layer parallelization. This increases the throughput up to three orders of magnitude and expands the geometric design space. We demonstrate this by printing, within single-digit millisecond time scales, nanowires with widths smaller than 175 nanometers over an area one million times larger than the cross-sectional area.

Evaluation of Parts Produced by a Novel Additive Manufacturing Process

2013 ◽  
Vol 315 ◽  
pp. 63-67 ◽  
Author(s):  
Muhammad Fahad ◽  
Neil Hopkinson
Keyword(s):  
Additive Manufacturing ◽  
Rapid Prototyping ◽  
Manufacturing Process ◽  
High Speed ◽  
Three Dimensional ◽  
Coordinate Measuring Machine ◽  
Layer By Layer ◽  
Nylon 12 ◽  
Measuring Machine ◽  
End Use

Rapid prototyping refers to building three dimensional parts in a tool-less, layer by layer manner using the CAD geometry of the part. Additive Manufacturing (AM) is the name given to the application of rapid prototyping technologies to produce functional, end use items. Since AM is relatively new area of manufacturing processes, various processes are being developed and analyzed for their performance (mainly speed and accuracy). This paper deals with the design of a new benchmark part to analyze the flatness of parts produced on High Speed Sintering (HSS) which is a novel Additive Manufacturing process and is currently being developed at Loughborough University. The designed benchmark part comprised of various features such as cubes, holes, cylinders, spheres and cones on a flat base and the build material used for these parts was nylon 12 powder. Flatness and curvature of the base of these parts were measured using a coordinate measuring machine (CMM) and the results are discussed in relation to the operating parameters of the process.The result show changes in the flatness of part with the depth of part in the bed which is attributed to the thermal gradient within the build envelope during build.

Increasing Part Accuracy in Additive Manufacturing Processes Using a k-d Tree Based Clustered Adaptive Layering

2014 ◽  
Vol 136 (6) ◽  
Author(s):  
Neeraj Panhalkar ◽  
Ratnadeep Paul ◽  
Sam Anand
Keyword(s):  
Additive Manufacturing ◽  
Computer Aided Design ◽  
Three Dimensional ◽  
Layer By Layer ◽  
Adaptive Slicing ◽  
Stl File ◽  
Build Time ◽  
Standard File Format ◽  
Aided Design ◽  
Profile Errors

Additive manufacturing (AM) is widely used in aerospace, automobile, and medical industries for building highly accurate parts using a layer by layer approach. The stereolithography (STL) file is the standard file format used in AM machines and approximates the three-dimensional (3D) model of parts using planar triangles. However, as the STL file is an approximation of the actual computer aided design (CAD) surface, the geometric errors in the final manufactured parts are pronounced, particularly in those parts with highly curved surfaces. If the part is built with the minimum uniform layer thickness allowed by the AM machine, the manufactured part will typically have the best quality, but this will also result in a considerable increase in build time. Therefore, as a compromise, the part can be built with variable layer thicknesses, i.e., using an adaptive layering technique, which will reduce the part build time while still reducing the part errors and satisfying the geometric tolerance callouts on the part. This paper describes a new approach of determining the variable slices using a 3D k-d tree method. The paper validates the proposed k-d tree based adaptive layering approach for three test parts and documents the results by comparing the volumetric, cylindricity, sphericity, and profile errors obtained from this approach with those obtained using a uniform slicing method. Since current AM machines are incapable of handling adaptive slicing approach directly, a “pseudo” grouped adaptive layering approach is also proposed here. This “clustered slicing” technique will enable the fabrication of a part in bands of varying slice thicknesses with each band having clusters of uniform slice thicknesses. The proposed k-d tree based adaptive slicing approach along with clustered slicing has been validated with simulations of the test parts of different shapes.

Advancements in Manufacturing Technology With Additive Manufacturing and Its Context With Industry 4.0

2021 ◽  
pp. 1-24
Author(s):  
Ganzi Suresh
Keyword(s):  
Additive Manufacturing ◽  
Industry 4.0 ◽  
Industrial Revolution ◽  
Three Dimensional ◽  
Metal Alloys ◽  
Layer By Layer ◽  
Post Processing ◽  
Clear Insight ◽  
Am Processes ◽  
Insight Into

Additive manufacturing (AM) is also known as 3D printing and classifies various advanced manufacturing processes that are used to manufacture three dimensional parts or components with a digital file in a sequential layer-by-layer. This chapter gives a clear insight into the various AM processes that are popular and under development. AM processes are broadly classified into seven categories based on the type of the technology used such as source of heat (ultraviolet light, laser) and type materials (resigns, polymers, metal and metal alloys) used to fabricate the parts. These AM processes have their own merits and demerits depending upon the end part application. Some of these AM processes require extensive post-processing in order to get the finished part. For this process, a separate machine is required to overcome this hurdle in AM; hybrid manufacturing comes into the picture with building and post-processing the part in the same machine. This chapter also discusses the fourth industrial revolution (I 4.0) from the perspective of additive manufacturing.

Stereolithographic Additive Manufacturing of Bulky Ceramic Components with Functionally Geometric Micropattern

2016 ◽  
Vol 2016 (CICMT) ◽  
pp. 000001-000005
Author(s):  
Soshu Kirihara
Keyword(s):  
Additive Manufacturing ◽  
Computer Aided Design ◽  
Three Dimensional ◽  
Laser Scanner ◽  
Porous Electrodes ◽  
Beam Diameter ◽  
Cross Sectional ◽  
Geometric Patterns ◽  
Artificial Bones ◽  
Cad Cam

Abstract In a stereolithographic additive manufacturing (AM), two dimensional (2D) cross sectional patterns were created through photo polymerization by ultraviolet laser drawing on spread resin paste including ceramic nanoparticles, and three dimensional (3D) composite models were sterically printed by layer lamination through chemical bonding. An automatic collimeter was equipped with the laser scanner to adjust beam diameter. Fine or coarse beams could realize high resolution or wide area drawings, respectively. Metal and ceramic bulky components including dendritic networks were geometrically built by using stereolithographic AM. Geometric patterns with periodic, self-similar, graded and fluctuated arrangements were created by computer aided design, manufacture and evaluation (CAD/CAM/CAE) for effective modulations of energy and material flows through dielectric lattices in photonic crystals, porous electrodes in fuel cells and biological scaffolds in artificial bones.

scholarly journals 4D Printing: A Review on Recent Progresses

Micromachines ◽  
2020 ◽  
Vol 11 (9) ◽  
pp. 796 ◽  
Author(s):  
Honghui Chu ◽  
Wenguang Yang ◽  
Lujing Sun ◽  
Shuxiang Cai ◽  
Rendi Yang ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Three Dimensional ◽  
Complex Structures ◽  
Future Prospects ◽  
4D Printing ◽  
Stimulation Method ◽  
Shape Property ◽  
External Stimuli

Since the late 1980s, additive manufacturing (AM), commonly known as three-dimensional (3D) printing, has been gradually popularized. However, the microstructures fabricated using 3D printing is static. To overcome this challenge, four-dimensional (4D) printing which defined as fabricating a complex spontaneous structure that changes with time respond in an intended manner to external stimuli. 4D printing originates in 3D printing, but beyond 3D printing. Although 4D printing is mainly based on 3D printing and become an branch of additive manufacturing, the fabricated objects are no longer static and can be transformed into complex structures by changing the size, shape, property and functionality under external stimuli, which makes 3D printing alive. Herein, recent major progresses in 4D printing are reviewed, including AM technologies for 4D printing, stimulation method, materials and applications. In addition, the current challenges and future prospects of 4D printing were highlighted.

Investigation of Parameter Spaces for Topology Optimization With Three-Dimensional Orientation Fields for Multi-Axis Additive Manufacturing

2020 ◽  
Vol 143 (5) ◽  
Author(s):  
Joseph R. Kubalak ◽  
Alfred L. Wicks ◽  
Christopher B. Williams
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Design Space ◽  
Mechanical Performance ◽  
Unit Length ◽  
Three Dimensions ◽  
Layer By Layer ◽  
Material Distribution ◽  
Orientation Fields ◽  
Material Orientation

Abstract The layer-by-layer deposition process used in material extrusion (ME) additive manufacturing results in inter- and intra-layer bonds that reduce the mechanical performance of printed parts. Multi-axis (MA) ME techniques have shown potential for mitigating this issue by enabling tailored deposition directions based on loading conditions in three dimensions (3D). Planning deposition paths leveraging this capability remains a challenge, as an intelligent method for assigning these directions does not exist. Existing literature has introduced topology optimization (TO) methods that assign material orientations to discrete regions of a part by simultaneously optimizing material distribution and orientation. These methods are insufficient for MA–ME, as the process offers additional freedom in varying material orientation that is not accounted for in the orientation parameterizations used in those methods. Additionally, optimizing orientation design spaces is challenging due to their non-convexity, and this issue is amplified with increased flexibility; the chosen orientation parameterization heavily impacts the algorithm’s performance. Therefore, the authors (i) present a TO method to simultaneously optimize material distribution and orientation with considerations for 3D material orientation variation and (ii) establish a suitable parameterization of the orientation design space. Three parameterizations are explored in this work: Euler angles, explicit quaternions, and natural quaternions. The parameterizations are compared using two benchmark minimum compliance problems, a 2.5D Messerschmitt–Bölkow–Blohm beam and a 3D Wheel, and a multi-loaded structure undergoing (i) pure tension and (ii) three-point bending. For the Wheel, the presented algorithm demonstrated a 38% improvement in compliance over an algorithm that only allowed planar orientation variation. Additionally, natural quaternions maintain the well-shaped design space of explicit quaternions without the need for unit length constraints, which lowers computational costs. Finally, the authors present a path toward integrating optimized geometries and material orientation fields resulting from the presented algorithm with MA–ME processes.

Mask-Less Electrochemical Additive Manufacturing: A Feasibility Study

2015 ◽  
Vol 137 (2) ◽  
Author(s):  
Murali M. Sundaram ◽  
Abishek B. Kamaraj ◽  
Varun S. Kumar
Keyword(s):  
Additive Manufacturing ◽  
Electrochemical Deposition ◽  
Pulse Wave ◽  
Three Dimensional ◽  
Layer By Layer ◽  
Simulation Studies ◽  
Feature Size ◽  
Metallic Structures ◽  
Wave Characteristics ◽  
Cad Models

Additive manufacturing (AM) of metallic structures by laser based layered manufacturing processes involve thermal damages. In this work, the feasibility of mask-less electrochemical deposition as a nonthermal metallic AM process has been studied. Layer by layer localized electrochemical deposition using a microtool tip has been performed to manufacture nickel microstructures. Three-dimensional free hanging structures with about 600 μm height and 600 μm overhang are manufactured to establish the process capability. An inhouse built CNC system was integrated in this study with an electrochemical cell to achieve 30 layers thick microparts in about 5 h by AM directly from STL files generated from corresponding CAD models. The layer thickness achieved in this process was about 10 μm and the minimum feature size depends on the tool width. Simulation studies of electrochemical deposition performed to understand the pulse wave characteristics and their effects on the localization of the deposits.

scholarly journals Novel diamond shuttle to deliver flexible bioelectronics with reduced tissue compression

2018 ◽  
Author(s):  
Kyounghwan Na ◽  
Zachariah J. Sperry ◽  
Jiaao Lu ◽  
Mihaly Vöröslakos ◽  
Saman S. Parizi ◽  
...  
Keyword(s):  
Nervous System ◽  
Dura Mater ◽  
Design Space ◽  
Three Dimensional ◽  
Neural Engineering ◽  
Cross Sectional ◽  
Vertical Support ◽  
Important Challenge ◽  
Tissue Compression

AbstractThe ability to deliver flexible biosensors through the toughest membranes of the central and peripheral nervous system is an important challenge in neuroscience and neural engineering. Bioelectronic devices implanted through dura mater and thick epineurium would ideally create minimal compression and acute damage as they reach the neurons of interest. We demonstrate that a three-dimensional diamond shuttle can be easily made with a vertical support to deliver ultra-compliant polymer microelectrodes (4.5 μm thick) in-vivo through dura mater and thick epineurium. The diamond shuttle has 54% less cross-sectional area than an equivalently stiff silicon shuttle, which we simulated will result in a 37% reduction in blood vessel damage. We also discovered that higher frequency oscillation of the shuttle (200 Hz) significantly reduced tissue compression regardless of the insertion speed, while slow speeds also independently reduced tissue compression. Insertion and recording performance are demonstrated in rat and feline models, but the large design space of these tools are suitable for research in a variety of animal models and nervous system targets.

scholarly journals A 3D weaving infill pattern for fused filament fabrication

2021 ◽  
Author(s):  
Yuan Yao ◽  
Cheng Ding ◽  
Mohamed Aburaia ◽  
Maximilian Lackner ◽  
Lanlan He
Keyword(s):  
Additive Manufacturing ◽  
Three Dimensional ◽  
Layer By Layer ◽  
Fused Filament Fabrication ◽  
Repetitive Structure ◽  
Mechanical Linkage ◽  
Manufacturing Technologies ◽  
Dimensional Object ◽  
Anisotropy Of Mechanical Properties ◽  
3D Weaving

Abstract The Fused Filament Fabrication process is the most used additive manufacturing process due to its simplicity and low operating costs. In this process, a thermoplastic filament is led through an extruder, melted, and applied to a building platform by the axial movements of an automated Cartesian system in such a way that a three-dimensional object is created layer by layer. Compared to other additive manufacturing technologies, the components produced have mechanical limitations and are often not suitable for functional applications. To reduce the anisotropy of mechanical strength in fused filament fabrication (FFF), this paper proposes a 3D weaving deposit path planning method that utilizes a 5-layer repetitive structure to achieve interlocking and embedding between neighbor slicing planes to improve the mechanical linkage within the layers. The developed algorithm extends the weaving path as an infill pattern to fill different structures and makes this process feasible on a standard three-axis 3D printer. Compared with 3D weaving printed parts by layer-to-layer deposit, the anisotropy of mechanical properties inside layers is significantly reduced to 10.21% and 0.98%.

scholarly journals Experimental Investigation on Mechanical Properties of Part Fabricated by Wire Arc Additive Manufacturing Process

2021 ◽  
Author(s):  
Vivek Kumar P ◽  
◽  
Soundrapandian E ◽  
Jenin Joseph A ◽  
Kanagarajan E ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Three Dimensional ◽  
Casting Process ◽  
Significant Rise ◽  
Layer By Layer ◽  
Cnc Machine ◽  
Hardness Tester ◽  
Wire Arc Additive Manufacturing

Additive manufacturing process is a method of layer by layer joining of materials to create components from three-dimensional (3D) model data. After their introduction in the automotive sector a decade ago, it has seen a significant rise in research and growth. The Additive manufacturing is classified into different types based upon the energy source use in the fabrication process. In our project, we used self-build CNC machine that runs MACH3 software, as well as the MACH3 controller is used to control the welding torch motion for material addition through three axis movement (X, Y and Z). In the project we used ER70 S-6 weld wire for the fabrication and examined its microstructure and mechanical properties. Different layers of the specimen had different microstructures, according to microstructural studies of the product. Rockwell hardness tester used for testing hardness of the product. According to the observation of the part fabricated components using the Wire Arc Additive Manufacturing process outperformed the mechanical properties of mild steel casting process. The product fabricated by Wire Arc Additive Manufacturing process properties is superior to conventional casting process.

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