Additive manufacturing (AM) has become more prominent in leading industries. Recently, there have been intense efforts to achieve a fully functional 3D structural electronic device by integrating conductive structures into AM parts. Here, we introduce a simple approach to creating a conductive layer on a polymer AM part by CO2 laser processing. Scanning electron microscopy (SEM), transmission electron microscopy (TEM), and Raman spectroscopy were employed to analyze laser-induced modifications in surface morphology and surface chemistry. The results suggest that conductive porous graphene was obtained from the AM-produced carbon precursor after the CO2 laser scanning. At a laser power of 4.5 W, the lowest sheet resistance of 15.9 Ω/sq was obtained, indicating the excellent electrical conductivity of the laser-induced graphene (LIG). The conductive graphene on the AM parts could serve as an electrical interconnection and shows a potential for the manufacturing of electronics components. An interdigital electrode capacitor was written on the AM parts to demonstrate the capability of LIG. Cyclic voltammetry, galvanostatic charge-discharge, and cyclability testing demonstrated good electrochemical performance of the LIG capacitor. These findings may create opportunities for the integration of laser direct writing electronic and additive manufacturing.
With the recent expansion of additive manufacturing (AM) in industries, there is an intense need to improve the surface quality of AM parts. A functional surface with extreme wettability would explore the application of AM in medical implants and microfluid. In this research, we propose to superimpose the femtosecond (fs) laser induced period surface structures (LIPSS) in the nanoscale onto AM part surfaces with the micro structures that are fabricated in the AM process. A hierarchical structure that has a similar morphology to a lotus leaf surface is obtained by combining the advantages of liquid assisting fs laser processing and AM. A water contact angle (WCA) of 150° is suggested so that a super hydrophobic surface is achieved. The scanning electron microscopy (SEM) images and X-ray photoelectron spectroscopy (XPS) analysis indicate that both hierarchical structures and higher carbon content in the laser processed area are responsible for the super hydrophobicity.
This paper investigates the orthotropic properties of Fused Deposition Modeling (FDM)-printed Acrylonitrile Styrene Acrylate (ASA) material with different raster configurations. The elastic properties were determined using a non-destructive ultrasonic technique. This technique allows us to deduce the orthotropic elastic constants from the material density and the velocities of the longitudinal and shear waves propagating through the material along different directions. Tensile tests were performed in addition to ultrasonic tests to obtain the yield properties of the ASA material and to validate the elastic constants determined by the ultrasonic tests, which have shown very close correspondence. Finally, numerical verification was performed by comparing the experimental results of the three-point and four-point bending tests with the finite element simulation results which have as input the material properties from the ultrasonic testing. The simulation results have shown excellent agreement with the experimental results, implying that the material properties obtained from the ultrasonic testing were highly accurate comparing to the actual orthotropic elastic properties of the 3D-printed ASA material.
Many studies have shown that the mechanical properties and geometric accuracy of additive manufacturing parts are dependence of many factors such as laser energy density, build orientation and heat transfer histories. Among the factors, heat transfer histories are highly dependent on the geometry of a part, resulting in influencing the mechanical properties and microstructure evolution due to repeated heating and cooling process. Heat transfer histories are associated with material thermal properties which includes thermal conductivity, thermal diffusivity, specific heat capacity and temperature gradient. The objective of this paper is to understand and observe the microstructure evolution process and micro-hardness based on variation in geometrical characteristic of the laser-based powder bed fusion (L-PBF). This paper presents the effect of the geometric factors on the mechanical properties and geometric accuracy during L-PBF process, which benefit future process optimization and modelling. In this study, samples with varying wall thickness are fabricated in TI6AL4Vand AlSi10Mg alloys by L-PBF. The samples are systematically evaluated by the optical microscope and Vickers hardness tester. Microstructural characterization of these samples is further evaluated via scanning electron microscopy. The results show that there is a signification relationship between material thermal properties, microstructure evolution and mechanical properties with respect to the variation in wall thickness. These results can be used to understand the material thermal behaviour in lattice structures with a thin or small size feature and serve as a design guideline to indirectly control the microstructure of a L-PBF part.
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