Development of an innovative, high speed, large-scaled, and affordable metal additive manufacturing process

Nguyen, Hoa Xuan; Suen, Hawke; Poudel, Bibek; Kwon, Patrick; Chung, Haseung

doi:10.1016/j.cirp.2020.04.069

Cited by 18 publications

(12 citation statements)

References 5 publications

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“…Peng et al demonstrated the printing of multifunctional structures and devices using an integrated DLP and direct ink writing (DLW) system [55] (Fig. 5b), whereas Nguyen et al presented the integration of DLP with binder jet printing (BJP) in their research for metal components manufacturing [56].…”

Section: Digital Light Processingmentioning

confidence: 99%

“…New DLP printers with coating/wiping blades and heating elements enable an increase in the powder content. At present, only a few studies [56,[118][119][120] have investigated the use of metallic suspension printed with DLP. However, a potential increase in the preparation of metal-based feedstocks can be seen to facilitate DLP technology with the competence to produce metallic parts.…”

Section: Metallic Feedstockmentioning

confidence: 99%

“…Metal sintering still needs to be systematically explored in the context of the DLP process, as only a few examples are available, e.g. stainless steel [56] and copper [119,120].…”

Section: Sinteringmentioning

confidence: 99%

“…Kim and Hwang et al reported a resolution of 76 ± 14 µm in dental prototypes using a DLP printer with 70 µm of XY resolution and 75 µm [141] (with permission from Elsevier), [142] (with permission from John Wiley and Sons), [143] (with permission from John Wiley and Sons) and [144] (with permission from Elsevier), respectively. Block e-h are adapted and reprinted from [145] (with permission from John Wiley and Sons), [56] (with permission from Elsevier), [146] (with permission from John Wiley and Sons) and [147] (licensed under a Creative Commons license, CC BY-NC 4.0), respectively layer thickness [149]. Among projection-based technologies, Janusziewicz et al introduced the CLIP method of AM using 0.4 µm slice thickness.…”

Section: Applicationsmentioning

confidence: 99%

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Additive manufacturing by digital light processing: a review

et al. 2022

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Additive manufacturing is a layer-by-layer strategy enabling the advanced design and fabrication of complex 3D objects and structures, overcoming geometry limitations and reducing waste production compared to conventional technologies. Among various additive manufacturing technologies, digital light processing (DLP), is an additive manufacturing technology used to print photopolymer parts, using a projected light source to cure an entire layer at once. Initially developed for pure resins, recent advances have demonstrated the potential of DLP in the polymerization of ceramic and metal-loaded suspensions, enabling the fabrication of ceramic and metal components after proper debinding and sintering. Such flexibility increases the potential of DLP for different applications, ranging from dental implants and bone scaffolds to smart biomaterials for soft robotics, smart wearables, and microfluidic devices. The review provides an overview of DLP technology and its recent advances; specifically, the review covers the photopolymer properties, the ceramic and metallic feedstock preparation, and the light-matter interaction mechanism underpinning the printing and post-processing steps. Finally, a description of the current application is provided and complemented with future perspectives.

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Section: Digital Light Processingmentioning

confidence: 99%

Section: Metallic Feedstockmentioning

confidence: 99%

“…Metal sintering still needs to be systematically explored in the context of the DLP process, as only a few examples are available, e.g. stainless steel [56] and copper [119,120].…”

Section: Sinteringmentioning

confidence: 99%

Section: Applicationsmentioning

confidence: 99%

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Additive manufacturing by digital light processing: a review

et al. 2022

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“…VP was developed predominantly for use with polymers 21 – 23 and has also been demonstrated for glasses 9 and ceramics 10 . However, inorganic material selection remains limited owing to challenges with incorporating appropriate precursors into photoresins as solutions 24 , slurries 25 or inorganic–organic mixtures 26 . Consequently, the fabrication of metals via VP remains a challenge.…”

Section: Mainmentioning

confidence: 99%

Additive manufacturing of micro-architected metals via hydrogel infusion

Saccone

Gallivan

Narita

et al. 2022

Nature

110

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Metal additive manufacturing (AM) enables the production of high value and high performance components 1 with applications from aerospace 2 to biomedical 3 fields. Layer-by-layer fabrication circumvents the geometric limitations of traditional metalworking techniques, allowing topologically optimized parts to be made rapidly and efficiently 4 , 5 . Existing AM techniques rely on thermally initiated melting or sintering for part shaping, a costly and material-limited process 6 – 8 . We report an AM technique that produces metals and alloys with microscale resolution via vat photopolymerization (VP). Three-dimensional-architected hydrogels are infused with metal precursors, then calcined and reduced to convert the hydrogel scaffolds into miniaturized metal replicas. This approach represents a paradigm shift in VP; the material is selected only after the structure is fabricated. Unlike existing VP strategies, which incorporate target materials or precursors into the photoresin during printing 9 – 11 , our method does not require reoptimization of resins and curing parameters for different materials, enabling quick iteration, compositional tuning and the ability to fabricate multimaterials. We demonstrate AM of metals with critical dimensions of approximately 40 µm that are challenging to fabricate by using conventional processes. Such hydrogel-derived metals have highly twinned microstructures and unusually high hardness, providing a pathway to create advanced metallic micromaterials.

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Additive Manufacturing of Micro‐Architected Copper based on an Ion‐Exchangeable Hydrogel

Ma,

Bai,

Xiong

et al. 2024

Angewandte Chemie

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Additive manufacturing (AM) of copper through laser‐based processes poses challenges, primarily attributed to the high thermal conductivity and low laser absorptivity of copper powder or wire as the feedstock. Although the use of copper salts in vat photopolymerization‐based AM techniques has garnered recent attention, achieving micro‐architected copper with high conductivity and density has remained elusive. In this study, we present a facile and efficient process to create complex 3D micro‐architected copper structures with superior electrical conductivity and hardness. The process entails the formulation of an ion‐exchangeable photoresin, followed by the utilization of digital light processing (DLP) printing to sculpt 3D hydrogel scaffolds, which were transformed into Cu2+‐chelated polymer frameworks (Cu‐CPFs) with a high loading of Cu2+ ions through ion exchange, followed by debinding and sintering, results in the transformation of Cu‐CPFs into miniaturized copper architectures. This methodology represents an efficient pathway for the creation of intricate micro‐architected 3D metal structures.

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Development of an innovative, high speed, large-scaled, and affordable metal additive manufacturing process

Cited by 18 publications

References 5 publications

Additive manufacturing by digital light processing: a review

Additive manufacturing by digital light processing: a review

Additive manufacturing of micro-architected metals via hydrogel infusion

Additive Manufacturing of Micro‐Architected Copper based on an Ion‐Exchangeable Hydrogel

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