Material Extrusion Additive Manufacturing of Metal Powder‐Based Inks Enabled by Carrageenan Rheology Modifier

Pack, Robert C.; Compton, Brett G.

doi:10.1002/adem.202000880

Cited by 12 publications

(5 citation statements)

References 43 publications

(46 reference statements)

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“…In Ref. [33] where AISI 316L scaffolds were printed by DIW using a carrageenan-based ink, the shear stress at yield showed a value of 4000 Pa. This value is in good agreement with the value measured for our ink (Table 2) formulated with B1, confirming this composition is well suited for porous structures.…”

Section: Ink Developmentsupporting

confidence: 85%

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Direct Ink Writing of AISI 316L Dense Parts and Porous Lattices

Biasetto

Elsayed

2022

Adv Eng Mater

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The production of metallic components by additive manufacturing (AM) technologies is today recognized as a standardized method, [1][2][3][4] especially when direct energy deposition (DED) and powder bed fusion (PBF) processes are employed. For instance, AM parts are currently produced by PBF and commercialized by GE Aviation; [5] by 2027 52% revenues of AM are expected to be covered by the aerospace, automotive, and energy sectors. [6] The difference between DED and PBF lies in the powder delivery mechanisms: in DED, the powder can be delivered as is or as a filament and melted on flight by a heat source, in PBF technologies a powder bed is selectively sintered (SLS) or melted (SLM) by a laser or electron beam (EBM). [6] The common points of PBF technologies are the use of micron-size gas atomized powders and the direct melting or sintering of the powders. If this represents an advantage in terms of printable geometries and production time, in contrast, the methods hide several side back effects: the need for a protective atmosphere to avoid oxidation, not all metals or alloy can be melted or sintered by the laser or electron beam power source, during printing hightemperature cooling rates (10 4 -10 5 K s À1 ) are responsible for the formation of metastable microstructures with consequences on the mechanical properties (anisotropy). The powders delivery mechanism does not allow the production of closed hollow shapes, so the laser path is responsible for poor control of surface roughness.In addition, PBF processes are not suitable for multi-material 3D printing, being this the next challenge for AM technologies. [7] For instance, powders delivery systems need to be redesigned to grant for proper multi-material combination.Another class of emerging technologies to 3D print metallic components are those classified as extrusion-based, where a metallic-based filament or paste is extruded through a nozzle at mild or room temperature. In both cases, gas-atomized metallic powders are mixed with a polymeric binder to obtain an extrudable filament or paste. In the first case, the technology is called fused deposition modeling (FDM, used for rapid prototyping) or fused filament fabrication (FFF), while in the second case it is called direct ink writing (DIW).FFF and DIW show the advantage of printing at mild or room temperature and the versatility to use more filaments or pastes, for instance, to 3D print multi-material components; the printed part must undergo a de-binding and sintering treatment to remove the polymeric binder and to densify the metallic powders into the final part. The preparation of a homogeneous and printable filament or paste remains one of the key points of these techniques, so de-binding and sintering must grant for the absence of organic binder residues. Sintering at high

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Section: Ink Developmentsupporting

confidence: 85%

“…Microhardness tests performed on the AISI316L‐B1 section showed an average value of 177 ± 15 HV, in good agreement with literature data of DIW‐printed AISI 316L specimens. [ 33 ] Further studies are forecast to define the amount of carbon content after sintering and its effect on the mechanical performance of the sintered components.…”

Section: Resultsmentioning

confidence: 99%

Direct Ink Writing of AISI 316L Dense Parts and Porous Lattices

Biasetto

Elsayed

2022

Adv Eng Mater

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“…Similar to FDM, DIW is also a high-efficiency method to deposit multi-material printed parts because it is of low cost and can be simply carried out [ 95 , 96 , 97 , 98 ]. More importantly, DIW exhibits tremendous potential because it is highly suitable for printing a large variety of different functional materials through multiple inkjet heads or nozzles to deposit different materials, including metallic particles [ 99 , 100 , 101 ], ceramic particles [ 102 , 103 , 104 ], extracellular matrices [ 105 , 106 , 107 , 108 ], hydrogels, and elastomers and epoxy thermosets [ 109 , 110 , 111 112 ]. As a result, DIW with multiple nozzles has become a favored candidate for multi-material 3D printing.…”

Section: Systematic Review Of Current Researchmentioning

confidence: 99%

Scientometric Analysis and Systematic Review of Multi-Material Additive Manufacturing of Polymers

et al. 2021

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Multi-material additive manufacturing of polymers has experienced a remarkable increase in interest over the last 20 years. This technology can rapidly design and directly fabricate three-dimensional (3D) parts with multiple materials without complicating manufacturing processes. This research aims to obtain a comprehensive and in-depth understanding of the current state of research and reveal challenges and opportunities for future research in the area. To achieve the goal, this study conducts a scientometric analysis and a systematic review of the global research published from 2000 to 2021 on multi-material additive manufacturing of polymers. In the scientometric analysis, a total of 2512 journal papers from the Scopus database were analyzed by evaluating the number of publications, literature coupling, keyword co-occurrence, authorship, and countries/regions activities. By doing so, the main research frame, articles, and topics of this research field were quantitatively determined. Subsequently, an in-depth systematic review is proposed to provide insight into recent advances in multi-material additive manufacturing of polymers in the aspect of technologies and applications, respectively. From the scientometric analysis, a heavy bias was found towards studying materials in this field but also a lack of focus on developing technologies. The future trend is proposed by the systematic review and is discussed in the directions of interfacial bonding strength, printing efficiency, and microscale/nanoscale multi-material 3D printing. This study contributes by providing knowledge for practitioners and researchers to understand the state of the art of multi-material additive manufacturing of polymers and expose its research needs, which can serve both academia and industry.

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“…In material extrusion (MEX), various particle sizes ranging from micro- [ 4 ] to nano-sized particles [ 5 ] can be used, unlike in PBF and BJT, which require spherical powders. In addition, MEX allows numerous types of powders to be used, such as ceramics and composite powders [ 5 ] or irregular shape of powders [ 6 ]. These characteristics render MEX favorable in the next-generation additive manufacturing.…”

Section: Introductionmentioning

confidence: 99%

Introduction to subpressure-driven soft deformation method for removing inherent voids in green components manufactured by material extrusion

Im,

Oh,

Goh

et al. 2024

Heliyon

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Material Extrusion Additive Manufacturing of Metal Powder‐Based Inks Enabled by Carrageenan Rheology Modifier

Cited by 12 publications

References 43 publications

Direct Ink Writing of AISI 316L Dense Parts and Porous Lattices

Direct Ink Writing of AISI 316L Dense Parts and Porous Lattices

Scientometric Analysis and Systematic Review of Multi-Material Additive Manufacturing of Polymers

Introduction to subpressure-driven soft deformation method for removing inherent voids in green components manufactured by material extrusion

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