Multi-Process Printing Method Combining Powder and Resin Based Additive Manufacturing

Whitehead, J. P.; Lipson, Hod

doi:10.1016/j.addlet.2022.100062

Cited by 4 publications

(5 citation statements)

References 21 publications

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“…[21] Whitehead and Lipson have combined the SLS and SLA processes and also suggested that conductive channels could be printed with the metal powder and then fused with the dielectric polymer resin. [22] All these approaches are very interesting, and each has its advantages and disadvantages. Here, we focus on the combination of FFF printing with extrusion (direct ink writing) printing.…”

Section: Doi: 101002/adem202301711mentioning

confidence: 99%

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Low‐Roughness 3D‐Printed Surfaces by Ironing for the Integration with Printed Electronics

Neuhaus,

Idris,

Naderi

et al. 2024

Adv Eng Mater

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The roughness of 3D‐printed surfaces poses a challenge when integrating fused filament fabrication (FFF) printing with printed electronics, leading to inconsistencies and breaks in the circuit traces. To improve the surface roughness, we propose an ironing toolpath. The ironing toolpath involves the hot nozzle going over the printed surface with finer line spacing, remelting the surface to fill gaps, and creating a smooth finish. For further optimization, various ironing parameters are investigated including flow, speed, line spacing, and temperature. A wide range of materials is tested, including commonly used low‐temperature filaments (PLA, PETG, ABS) and high‐temperature filaments (PSU, PEI, PEEK) suitable for integration with printed electronics and medical applications. To collect the extensive datasets an automated measurement system is deployed. With this method, surface roughness reductions of up to 96.6% are achieved and significant trends are identified. Lastly, the integration of 3D printing with electronics is demonstrated by printing a high‐resolution strain gauge structure on top of an ironed surface and embedding it into fully printed tweezers which could be used in medical robotics. The insights on ironing extend beyond electronics and can also be valuable in other areas where low surface roughness of FFF‐printed parts is required.This article is protected by copyright. All rights reserved.

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Section: Doi: 101002/adem202301711mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Low‐Roughness 3D‐Printed Surfaces by Ironing for the Integration with Printed Electronics

Neuhaus,

Idris,

Naderi

et al. 2024

Adv Eng Mater

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“…Alternatively, a metallic structure with intricate interlock features can be fabricated by powder bed fusion and subsequently printed with polymer features via material extrusion [47]. Besides metal and polymer, two different polymer types such as photopolymer resin and thermoplastic powder can also be combined via hybrid manufacturing to obtain PBF strength and VP surface finish [48].…”

Section: Hybrid Additive Manufacturingmentioning

confidence: 99%

Multi-material and Multi-dimensional 3D Printing for Biomedical Materials and Devices

Leong

2022

Biomedical Materials & Devices

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In recent years, Additive Manufacturing (AM) has evolved into a "multi-x" era, such as multi-part design, multi-material, multi-process, multi-mode, multi-scale, multi-dimension, and multi-function. These emerging new features of AM present both tremendous opportunities and challenges for developing and regulating new and novel biomedical materials and devices. This paper focuses on two aspects, namely multi-material and multi-dimension AM. In multi-material 3D printing, the layering step is the key. Modifying the layering method yet without changing the solidifying or bonding principles governing the AM process can enable and significantly advance multi-material 3D printing. In multi-dimensional 3D printing, typically 4D printing and 5D printing, the meaning of "D" is suggested to refer to space-time dimension rather than the number of degrees of freedom in physical space. It is proposed in this paper that an alternative dimension (or 5D) for future 3D printing processes can be that of scale. Scale here refers the different levels of resolution that are used simultaneously within a print. In such a scale dimension, continuous printing of cross-scale or varied resolution design features in a single build process without affecting the overall printing speed and time would be highly desirable. This is probably the first paper reflecting on multi-material 3D printing from the perspective of layering and on multi-dimensional 3D printing with regard to its future development.

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“…The substrate can then be lifted off the part, the material on the glass can be replenished, and the process can be repeated, with material in the new powder layer being fused to material in the previous layer.Since this process stacks successive layers of material without using a powder bed, the printed part is fully exposed and visible during the entire process. Therefore, unlike traditional SLA and FDM printers, failure can easily be detected in real time and addressed or aborted, eliminating wasted time and materials 14,15 .In previous work [16][17][18] , we showed how this process could be used to additively manufacture polymer parts (Fig. 1).…”

mentioning

confidence: 96%

“…In previous work [16][17][18] , we showed how this process could be used to additively manufacture polymer parts (Fig. 1).…”

mentioning

confidence: 99%

Inverted laser sintering of metal powders

Whitehead,

Lipson

2023

Sci Rep

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We demonstrate the ability of the inverted laser sintering process to manufacture parts composed of metal powder. We fabricate a 10-layer part by depositing a layer of copper powder onto a sapphire plate, then pressing the plate against the part being built and sintering the powder onto the part by shining a 14W 445 nm laser through the glass. The process was then repeated multiple times, each time adding a new layer to the component being printed until completion. We discuss the potential applications and impacts of this process, including the ability to directly fabricate multi-material metallic parts without the use of a powder bed.

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Multi-Process Printing Method Combining Powder and Resin Based Additive Manufacturing

Cited by 4 publications

References 21 publications

Low‐Roughness 3D‐Printed Surfaces by Ironing for the Integration with Printed Electronics

Low‐Roughness 3D‐Printed Surfaces by Ironing for the Integration with Printed Electronics

Multi-material and Multi-dimensional 3D Printing for Biomedical Materials and Devices

Inverted laser sintering of metal powders

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