3D printing for polymer/particle-based processing: A review

Xu, Weiheng; Jambhulkar, Sayli; Zhu, Yuxiang; Ravichandran, Dharneedar; Kakarla, Mounika; Vernon, Brent L.; Lott, David G.; Cornella, Jeffrey L.; Shefi, Orit; Miquelard‐Garnier, Guillaume; Yang, Yang; Song, Kenan

doi:10.1016/j.compositesb.2021.109102

Cited by 192 publications

(103 citation statements)

References 226 publications

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“…However, so far the resolution (the smallest feature size controllable) has been on the order of hundreds of micrometers, although the integration of nanostructures into 3D-printed materials or patterns is possible. [9][10][11][12][13][14][15][16][17][18] In other words, 3D printing is several orders of magnitude away from the feature sizes accessible by lithographic methods. In summary, 3D printing has the direct pattern generation capability and materials versatility, whereas Additive manufacturing (3D printing) has not been applicable to micro-and nanoscale engineering due to the limited resolution.…”

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confidence: 99%

Additive Manufacturing in Atomic Layer Processing Mode

et al. 2022

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are generated by a repetitive sequence of processing steps in which for each material a sacrificial resist layer is deposited, then patterned, then used to transfer its pattern into the desired material layer, and finally removed. This framework does not allow for the direct deposition of a patterned functional material. Its reliance on a small number of sacrificial "resists" and the multiple removal and cleaning steps cause large amounts of material waste. It also requires significant resources of energy, processing time, and facility investment. Additionally, lithography-based fabrication is highly suitable to the generation of identical products in large numbers, but it does not offer prompt access and flexibility to prototyping individual devices. In the manufacturing of large parts, prototyping has been rendered increasingly accessible using additive manufacturing (3D printing) strategies. [4][5][6][7][8] Here, the functional material is directly deposited in patterned form using various strategies such as miniaturized nozzles and laser or electron beams. However, so far the resolution (the smallest feature size controllable) has been on the order of hundreds of micrometers, although the integration of nanostructures into 3D-printed materials or patterns is possible. [9][10][11][12][13][14][15][16][17][18] In other words, 3D printing is several orders of magnitude away from the feature sizes accessible by lithographic methods. In summary, 3D printing has the direct pattern generation capability and materials versatility, whereas Additive manufacturing (3D printing) has not been applicable to micro-and nanoscale engineering due to the limited resolution. Atomic layer deposition (ALD) is a technique for coating large areas with atomic thickness resolution based on tailored surface chemical reactions. Thus, combining the principles of additive manufacturing with ALD could open up a completely new field of manufacturing. Indeed, it is shown that a spatially localized delivery of ALD precursors can generate materials patterns. In this "atomic-layer additive manufacturing" (ALAM), the vertical resolution of the solid structure deposited is about 0.1 nm, whereas the lateral resolution is defined by the microfluidic gas delivery. The ALAM principle is demonstrated by generating lines and patterns of pure, crystalline TiO 2 and Pt on planar substrates and conformal coatings of 3D nanostructures. The functional quality of ALAM patterns is exemplified with temperature sensors, which achieve a performance similar to the industry standard. This general method of multimaterial direct patterning is much simpler than standard multistep lithographic microfabrication. It offers process flexibility, saves processing time, investment, materials, waste, and energy. It is envisioned that together with etching, doping, and cleaning performed in a similar local manner, ALAM will create the "atomic-layer advanced manufacturing" family of techniques.The ORCID identification number(s) for the author(s) of this article can be found und...

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Additive Manufacturing in Atomic Layer Processing Mode

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“… 21 After the growth, the Si NWs were thermally oxidized in a convection oven (controlled O 2 atmosphere) at 980 °C for 8 h to form SiO 2 NWs. 22 , 30 …”

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confidence: 99%

High-Resolution 3D Fabrication of Glass Fiber-Reinforced Polymer Nanocomposite (FRPN) Objects by Two-Photon Direct Laser Writing

Ritacco

Cianni

Perziano

et al. 2022

ACS Appl. Mater. Interfaces

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This paper reports on the nanofabrication of a fiber-reinforced polymer nanocomposite (FRPN) by two-photon direct laser writing (TP-DLW) using silica nanowires (SiO 2 NWs) as nanofillers, since they feature a refractive index very close to that of the photoresist used as a polymeric matrix. This allows for the best resolution offered by the TP-DLW technique, even with high loads of SiO 2 NWs, up to 70 wt %. The FRPN presented an increase of approximately 4 times in Young’s modulus (8.23 GPa) and nanohardness (120 MPa) when compared to those of the bare photoresist, indicating how the proposed technique is well-suited for applications with higher structural requirements. Moreover, three different printing configurations can be implemented thanks to the use of silicon chips, on which the SiO 2 NWs are grown, as fabrication substrates. First, they can be effectively used as an adhesive layer when the laser beam is focused at the interface with the silicon substrate. Second, they can be used as a sacrificial layer, when the laser beam is focused in a plane inside the SiO 2 NW layer. Third, only the outer shell of the object is printed so that the SiO 2 NW tangle acts as the internal skeleton for the structure being fabricated in the so-called shell and scaffold printing strategy.

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“…Their intricate spinneret design was through Polyjet 3D printing that conventional tooling engineering finds time‐consuming and expensive 14 . Other additive manufacturing methods of selective laser sintering, stereolithography and fused deposition modeling (FDM) have all contributed to the user customization of spinneret design for unique fiber microstructures and applications 15–18 …”

Section: Introductionmentioning

confidence: 99%

A mini‐review of microstructural control during composite fiber spinning

Jambhulkar

Ravichandran

et al. 2022

Polymer International

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From wool to Kevlar, one‐dimensional (1D) fiber has experienced the transition from clothing materials to structural applications in the past centuries. However, the recent advancements in tooling engineering and manufacturing processes have attracted much attention from both academia and industry to fabricate novel, versatile fibers with unique microstructures and unprecedented properties. This mini‐review focuses on the fabrication techniques of porous, coaxial, layer‐by‐layer and segmented fibers with continuous solution and melt fiber spinning methods. In each section of this review article, the unique structure‐related applications, including intelligent devices, healthcare devices, energy storage systems, wearable electronics and sustainable products, are discussed and evaluated. Finally, the combination of additive manufacturing for 1D fiber patterning in two‐dimensional and three‐dimensional devices, in addition to challenges in the reviewed fiber microstructures, is briefly introduced in the conclusion. © 2021 Society of Industrial Chemistry.

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3D printing for polymer/particle-based processing: A review

Cited by 192 publications

References 226 publications

Additive Manufacturing in Atomic Layer Processing Mode

Additive Manufacturing in Atomic Layer Processing Mode

High-Resolution 3D Fabrication of Glass Fiber-Reinforced Polymer Nanocomposite (FRPN) Objects by Two-Photon Direct Laser Writing

A mini‐review of microstructural control during composite fiber spinning

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