Towards microwave volumetric additive manufacturing: Generation of a computational multi-physics model for localized curing
Not Available
Mukherjee, Saptarshi (ORCID:0000000306841356)↗
Engineering topics
Spadaccini, Christopher M.
Publications and source records attributed to Spadaccini, Christopher M..
Toward Multiscale, Multimaterial 3D Printing
Biological materials and organisms possess the fundamental ability to self-organize, through which different components are assembled from the molecular level up to hierarchical structures with superior mechanical properties and multifunctionalities. These complex composites inspire material scientists to design new engineered materials by integrating multiple ingredients and structures over a wide range. Additive manufacturing, also known as 3D printing, has advantages with respect to fabricating multiscale and multi-material structures. The need for multifunctional materials is driving 3D printing techniques toward arbitrary 3D architectures with the next level of complexity. In this paper, the aim is to highlight key features of those 3D printing techniques that can produce either multiscale or multimaterial structures, including innovations in printing methods, materials processing approaches, and hardware improvements. Several issues and challenges related to current methods are discussed. Ultimately, the authors also provide their perspective on how to realize the combination of multiscale and multimaterial capabilities in 3D printing processes and future directions based on emerging research.
36 MATERIALS SCIENCE↗
Multi-beam resin curing system and method for whole-volume additive manufacturing
A multi-beam volumetric resin curing system and method for whole-volume additive manufacturing of an object includes a bath containing a photosensitive resin, a light source for producing a light beam, and a spatial light modulator which produces a phase- or intensity-modulated light beam by impressing a phase profile or intensity profile of an image onto a light beam received from the light source. The system and method also include projection optics which then produces multiple sub-image beams from the modulated light beam which are projected to intersect each other in the photosensitive resin to cure select volumetric regions of the resin in a whole-volume three-dimensional pattern representing the object.
Shusteff, Maxim↗
Multimaterial powder bed patterning for additive manufacturing method
The present disclosure relates to an additive manufacturing system. In one embodiment the system makes use of a reservoir for holding a granular material feedstock. A nozzle is in communication with the reservoir for releasing the granular material feedstock in a controlled fashion from the reservoir to form at least one layer of a part. An excitation source is included for applying a signal which induces a controlled release of the granular material feedstock from the nozzle as needed, to pattern the granular material feedstock as necessary to form a layer of the part.
Dudukovic, Nikola↗
Engineering catalytical electrodes for applications in energy areas
An ink formulation and electrode that enhances hydrogen production, oxygen production, carbon dioxide reduction and other electrocatalytic reactions. Embodiments include an ink formulation with polymer binders having different catalytical precursors and a 3D electrode produced by additive manufacturing from the inventor's ink formulation. Various embodiments of the inventor's apparatus, systems, and methods provide inks that that are 3D-printed into patterns that optimize surface area and flow. The catalytic materials are imbedded into the ink matrix which is then printed into a 3D structure that has architecture that optimizes surface area and flow properties.
Liang, Siwei↗
Photocurable resins for volumetric additive manufacturing
Methods and materials for volumetric additive manufacturing, including computed axial lithography (“CAL”), using photosensitive resins comprising a photocurable resin prepolymer; a photoinitiator; and (optionally) a curing inhibitor. In various embodiments, such photosensitive polymers comprise (a) one or more monomer (or prepolymer) molecules, which form the backbone of the polymer network of the polymeric material and define its architecture; and (b) a photoinitiator that captures illumination energy and initiates polymerization.
Shusteff, Maxim↗
Laser pulse shaping for additive manufacturing
The present disclosure relates to an apparatus for additively manufacturing a product in a layer-by-layer sequence, wherein the product is formed using powder particles deposited on an interface layer of a substrate. A laser generates first and second beam components. The second beam component has a higher power level and a shorter duration than the first beam component. A mask creates a 2D optical pattern in which only select portions of the second beam components can irradiate the powder particles. The first beam component heats the powder particles close to a melting point, where the particles experience surface tension forces relative to the interface layer. While the particles are heated, the second beam component further heats the particles and also melts the interface layer before the surface tension forces can act on and distort the particles, enabling the particles and the interface layer are able to bond together.
DeMuth, James A.↗
Selective Heating Through Y-Junction Waveguide Designed by Acoustic Shape Optimization
Unlike phononic crystals or systems designed by topology optimization, waveguides designed by shape optimization do not have voids or internal defects, making the fabrication process more suitable for additive manufacturing. By designing a Y-junction waveguide through shape optimization, an ultrasonic wave can be controlled so that it propagates to a predetermined location just by adjusting its frequency. These demultiplexed ultrasonic waves can be used to transport signals or stimulate nearby materials. As an example, the ultrasonic wave is converted to heat at different locations, which can be applied to mechanisms that can take advantage of heating. First, shape optimization is performed on a cylindrical structure to selectively propagate ultrasonic waves of a particular frequency while attenuating others, which is analyzed through a finite element model. The numerical study results are compared with experimental measurements from samples fabricated through additive manufacturing methods. After verifying the concept, the Y-junction waveguide is fabricated to demultiplex the wave and selectively heat different locations. Here the results show that the method of combining shape optimization with additive manufacturing is exceptionally simple and capable of demultiplexing ultrasonic waves, which can replace complex electrical components with single-material waveguides.
36 MATERIALS SCIENCE↗
Systems and methods for additive manufacturing to encapsulate transformative colloidal suspensions
The present disclosure relates to an energy absorbing three dimensional (3D) structure. The structure may have an outer shell formed from a shell material. The outer shell may have a void forming a core volume. A transformative feedstock is contained in the void. The transformative feedstock is encapsulated within the outer shell, within the void, and provides enhanced energy absorbing properties to the 3D structure.
Mancini, Julie A.↗
Hierarchical porous metals with deterministic 3D morphology and shape via de-alloying of 3D printed alloys
The present disclosure relates to a method for forming a three dimensional, hierarchical, porous metal structure with deterministically controlled 3D multiscale pore architectures. The method may involve providing a feedstock able to be applied in an additive manufacturing process, and using an additive manufacturing process to produce a three dimensional (3D) structure using the feedstock. The method may involve further processing the 3D structure through at least a de-alloying operation to form a metallic 3D structure having an engineered, digitally controlled macropore morphology with integrated nanoporosity.
Qi, Zhen↗
Perspectives on multi-material additive manufacturing
The last two decades have seen enormous gains in industrial adoption of additive manufacturing (AM) technologies. Its layer-wise approach to fabrication offers designers the opportunity to create structures with unique performance advantages over their traditionally manufactured counterparts, and have created new manufacturing business models and supply chains. While today’s AM technologies have enabled the creation of new geometries, future AM systems that offer simultaneous processing of multiple materials in a single build open opportunities for new product functionality that cannot be achieved by traditional manufacturing methods. Advances in multi-material additive manufacturing, which integrate dissimilar material into a complex, three-dimensional object, is emerging but the advances have been sporadic. Moving beyond homogenous materials, adding multi-materials, gradient, functional and responsive materials, and materials with heterogeneous and graded properties means that a single additive process based on either energy delivery or material deposition alone may not be suitable. Finally, this perspective gives a brief overview of the current status, challenges, and future recommendations for multi-material additive manufacturing. The authors aim to expand the notion of multi-material additive manufacturing beyond combining materials with dissimilar properties, to combinations of materials at different length scales, material classes as well as multiple functionalities.
36 MATERIALS SCIENCE↗
Separation of a target substance from a fluid or mixture using encapsulated sorbents
Method and apparatus for separating a target substance from a fluid or mixture. Capsules having a coating and stripping solvents encapsulated in the capsules are provided. The coating is permeable to the target substance. The capsules having a coating and stripping solvents encapsulated in the capsules are exposed to the fluid or mixture. The target substance migrates through the coating and is taken up by the stripping solvents. The target substance is separated from the fluid or mixture by driving off the target substance from the capsules.
Aines, Roger D.↗
Performance of three-dimensional printed nasopharyngeal swabs for COVID-19 testing
At the start of the COVID-19 pandemic, the US faced nationwide shortages of nasopharyngeal swabs due to both overwhelmed supply chains and an increase in demand. To address this shortfall, multiple 3D printed swabs were ultimately produced and sold for COVID-19 testing. In this work, we present a framework for mechanical and functional bench-testing of nasopharyngeal swabs using standard and widely available material testing equipment. Using this framework, we offer a comprehensive, quantitative comparison of the 3D printed swabs to benchmark their performance against traditional flocked swabs. The test protocols were designed to emulate the clinical use of the nasopharyngeal swabs and to evaluate potential failure modes. Overall, the 3D printed swabs performed comparably to, or outperformed, the traditional swabs in all mechanical tests. While traditional swabs outperformed some of the new 3D printed swabs in terms of sample uptake and retention, similar amounts of RNA were recovered from both 3D printed and traditional swabs.
3D printing↗
System and method for stimulated emission depletion projection stereolithography
The present disclosure relates to a system for forming a three dimensional (3D) part. The system may incorporate a beam delivery subsystem for generating optical signals, and a mask subsystem that receives the optical signals and generates optical images therefrom. A first one of the optical images activates a polymerization species of a photo-sensitive resin in accordance with illuminated areas thereof, to thus cause polymerization of select portions of the photo-sensitive resin to help form a layer of the 3D part. A second one of the optical images causes stimulated emission depletion of subportions of the polymerization species, simultaneously, over various areas of the layer, to enhance resolution of at least one subportion of the select portions of the photo-sensitive resin.
Hensleigh, Ryan↗
Method of fabricating a three-dimensionally patterned mechanical energy absorptive material
A three-dimensionally patterned energy absorptive material and fabrication method having multiple layers of patterned filaments extrusion-formed from a curable pre-cursor material and stacked and cured in a three-dimensionally patterned architecture so that the energy absorptive material produced thereby has an engineered bulk property associated with the three-dimensionally patterned architecture.
Duoss, Eric B.↗
Neutron generation using pyroelectric crystals
According to one embodiment, a method for producing a directed neutron beam includes producing a voltage of negative polarity of at least −100 keV on a surface of a deuterated or tritiated target in response to a temperature change of a pyroelectric crystal of less than about 40° C., the pyroelectric crystal having the deuterated or tritiated target coupled thereto, pulsing a deuterium ion source to produce a deuterium ion beam, accelerating the deuterium ion beam to the deuterated or tritiated target to produce a neutron beam, and directing the ion beam onto the deuterated or tritiated target to make neutrons using at least one of a voltage of the pyroelectric crystal, and a high gradient insulator (HGI) surrounding the pyroelectric crystal. The directionality of the neutron beam is controlled by changing the accelerating voltage of the system. Other methods are presented as well.
Tang, Vincent↗
Systematic Design and Experimental Demonstration of Transmission-Type Multiplexed Acoustic Metaholograms
Acoustic holograms have promising applications in sound-field reconstruction, particle manipulation, ultrasonic haptics, and therapy. This study reports on the theoretical, numerical, and experimental investigation of multiplexed acoustic holograms at both audio and ultrasonic frequencies via a rationally designed transmission-type acoustic metamaterial. The proposed metahologram is composed of two Fabry–Pérot resonant channels per unit cell, which enables the simultaneous modulation of the transmitted amplitude and phase at two desired frequencies. In contrast to conventional acoustic metamaterial-based holograms, the design strategy proposed here provides a new degree of freedom (frequency) that can actively tailor holograms that are otherwise completely passive and significantly enhances the information encoded in acoustic metamaterials. To demonstrate the multiplexed acoustic metamaterial, the projection of two different high-quality metaholograms is first shown at 14 and 17 kHz, with the patterns of the letters N and S. Then, two-channel ultrasound focusing and annular beams generation for the incident ultrasonic frequencies of 35 and 42.5 kHz are demonstrated. Furthermore, these multiplexed acoustic metaholograms offer a technical advance to tackle the rising challenges in the fields of acoustic metamaterials, architectural acoustics, and medical ultrasound.
36 MATERIALS SCIENCE↗
3D Printed Nickel–Molybdenum-Based Electrocatalysts for Hydrogen Evolution at Low Overpotentials in a Flow-Through Configuration
Three-dimensional (3D) printed, hierarchically porous nickel molybdenum (NiMo) electrocatalysts were synthesized and evaluated in a flow-through configuration for the hydrogen evolution reaction (HER) in 1.0 M KOH(aq) in a simple electrochemical H-cell. 3D NiMo electrodes possess hierarchically porous structures because of the resol-based aerogel precursor, which generates superporous carbon aerogel as a catalyst support. Relative to a traditional planar electrode configuration, the flow-through configuration allowed efficient removal of the hydrogen bubbles from the catalyst surface, especially at high operating current densities, and significantly decreased the overpotentials required for HER. An analytical model that accounted for the electrokinetics of HER as well as the mass transport with or without the flow-through configuration was developed to quantitatively evaluate voltage losses associated with kinetic overpotentials and ohmic resistance due to bubble formation in the porous electrodes. Furthermore, the chemical composition, electrochemical surface area (ECSA), and roughness factor (RF) were also systematically studied to assess the electrocatalytic performance of the 3D printed, hierarchically porous NiMo electrodes. An ECSA of 25163 cm2 was obtained with the highly porous structures, and an average overpotential of 45 mV at 10 mA cm–2 was achieved over 24 h by using the flow-through configuration. The flow-through configuration evaluated in the simple H-cell achieved high electrochemical accessible surface areas for electrochemical reactions and provided useful information for adaption of the porous electrodes in flow cells.
08 HYDROGEN↗