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Zhu C, Gemeda HB, Duoss EB, Spadaccini CM. Toward Multiscale, Multimaterial 3D Printing. ADVANCED MATERIALS (DEERFIELD BEACH, FLA.) 2024:e2314204. [PMID: 38775924 DOI: 10.1002/adma.202314204] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 12/26/2023] [Revised: 04/11/2024] [Indexed: 06/06/2024]
Abstract
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.
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Affiliation(s)
- Cheng Zhu
- Center for Engineered Materials and Manufacturing, Materials Engineering Division, Lawrence Livermore National Laboratory, 7000 East Ave, Livermore, CA, 94550, USA
| | - Hawi B Gemeda
- Center for Engineered Materials and Manufacturing, Materials Engineering Division, Lawrence Livermore National Laboratory, 7000 East Ave, Livermore, CA, 94550, USA
| | - Eric B Duoss
- Center for Engineered Materials and Manufacturing, Materials Engineering Division, Lawrence Livermore National Laboratory, 7000 East Ave, Livermore, CA, 94550, USA
| | - Christopher M Spadaccini
- Center for Engineered Materials and Manufacturing, Materials Engineering Division, Lawrence Livermore National Laboratory, 7000 East Ave, Livermore, CA, 94550, USA
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Wu L, Dong Z. Interfacial Regulation for 3D Printing based on Slice-Based Photopolymerization. ADVANCED MATERIALS (DEERFIELD BEACH, FLA.) 2023:e2300903. [PMID: 37147788 DOI: 10.1002/adma.202300903] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 01/30/2023] [Revised: 02/21/2023] [Indexed: 05/07/2023]
Abstract
3D printing, also known as additive manufacturing, can turn computer-aided designs into delicate structures directly and on demand by eliminating expensive molds, dies, or lithographic masks. Among the various technical forms, light-based 3D printing mainly involved the control of polymer-based matter fabrication and realized a field of manufacturing with high tunability of printing format, speed, and precision. Emerging slice- and light-based 3D-printing methods have prosperously advanced in recent years but still present challenges to the versatility of printing continuity, printing process, and printing details control. Herein, the field of slice- and light-based 3D printing is discussed and summarized from the view of interfacial regulation strategies to improve the printing continuity, printing process control, and the character of printed results, and several potential strategies to construct complex 3D structures of distinct characteristics with extra external fields, which are favorable for the further improvement and development of 3D printing, are proposed.
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Affiliation(s)
- Lei Wu
- Key Laboratory of Green Printing, Beijing National Laboratory for Molecular Sciences (BNLMS), Institute of Chemistry, Chinese Academy of Sciences, Beijing, 100190, P. R. China
- CAS Key Laboratory of Bio-inspired Materials and Interfacial Science, Technical Institute of Physics and Chemistry, Chinese Academy of Sciences, Beijing, 100190, P. R. China
| | - Zhichao Dong
- CAS Key Laboratory of Bio-inspired Materials and Interfacial Science, Technical Institute of Physics and Chemistry, Chinese Academy of Sciences, Beijing, 100190, P. R. China
- School of Future Technology, University of Chinese Academy of Sciences, Beijing, 100049, P. R. China
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3
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Kim WY, Seo BW, Lee SH, Lee TG, Kwon S, Chang WS, Nam SH, Fang NX, Kim S, Cho YT. Quasi-seamless stitching for large-area micropatterned surfaces enabled by Fourier spectral analysis of moiré patterns. Nat Commun 2023; 14:2202. [PMID: 37072425 PMCID: PMC10113184 DOI: 10.1038/s41467-023-37828-8] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/15/2022] [Accepted: 04/03/2023] [Indexed: 04/20/2023] Open
Abstract
The main challenge in preparing a flexible mold stamp using roll-to-roll nanoimprint lithography is to simultaneously increase the imprintable area with a minimized perceptible seam. However, the current methods for stitching multiple small molds to fabricate large-area molds and functional surfaces typically rely on the alignment mark, which inevitably produces a clear alignment mark and stitched seam. In this study, we propose a mark-less alignment by the pattern itself method inspired by moiré technique, which uses the Fourier spectral analysis of moiré patterns formed by superposed identical patterns for alignment. This method is capable of fabricating scalable functional surfaces and imprint molds with quasi-seamless and alignment mark-free patterning. By harnessing the rotational invariance property in the Fourier transform, our approach is confirmed to be a simple and efficient method for extracting the rotational and translational offsets in overlapped periodic or nonperiodic patterns with a minimized stitched region, thereby allowing for the large-area and quasi-seamless fabrication of imprinting molds and functional surfaces, such as liquid-repellent film and micro-optical sheets, that surpass the conventional alignment and stitching limits and potentially expand their application in producing large-area metasurfaces.
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Affiliation(s)
- Woo Young Kim
- Department of Smart Manufacturing Engineering, Changwon National University, Changwon, South Korea
| | - Bo Wook Seo
- Department of Smart Manufacturing Engineering, Changwon National University, Changwon, South Korea
| | - Sang Hoon Lee
- Department of Smart Manufacturing Engineering, Changwon National University, Changwon, South Korea
| | - Tae Gyung Lee
- Department of Smart Manufacturing Engineering, Changwon National University, Changwon, South Korea
| | - Sin Kwon
- Department of Flexible & Printed Electronics, Korea Institute of Machinery and Materials, Daejeon, South Korea
| | - Won Seok Chang
- Department of Nano Manufacturing Technology, Korea Institute of Machinery and Materials, Daejeon, South Korea
- Department of Nanomechatronics, University of Science and Technology, Daejeon, South Korea
| | - Sang-Hoon Nam
- Department of Mechanical Engineering, Massachusetts Institute of Technology, Cambridge, MA, USA
| | - Nicholas X Fang
- Department of Mechanical Engineering, Massachusetts Institute of Technology, Cambridge, MA, USA
- Department of Mechanical Engineering, The University of Hong Kong, Hong Kong, Hong Kong, Special Administrative Region of China
| | - Seok Kim
- Department of Smart Manufacturing Engineering, Changwon National University, Changwon, South Korea.
- Department of Mechanical Engineering, Changwon National University, Changwon, South Korea.
| | - Young Tae Cho
- Department of Smart Manufacturing Engineering, Changwon National University, Changwon, South Korea.
- Department of Mechanical Engineering, Changwon National University, Changwon, South Korea.
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Su R, Chen J, Zhang X, Wang W, Li Y, He R, Fang D. 3D-Printed Micro/Nano-Scaled Mechanical Metamaterials: Fundamentals, Technologies, Progress, Applications, and Challenges. SMALL (WEINHEIM AN DER BERGSTRASSE, GERMANY) 2023:e2206391. [PMID: 37026433 DOI: 10.1002/smll.202206391] [Citation(s) in RCA: 4] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 10/17/2022] [Revised: 02/08/2023] [Indexed: 06/19/2023]
Abstract
Micro/nano-scaled mechanical metamaterials have attracted extensive attention in various fields attributed to their superior properties benefiting from their rationally designed micro/nano-structures. As one of the most advanced technologies in the 21st century, additive manufacturing (3D printing) opens an easier and faster path for fabricating micro/nano-scaled mechanical metamaterials with complex structures. Here, the size effect of metamaterials at micro/nano scales is introduced first. Then, the additive manufacturing technologies to fabricate mechanical metamaterials at micro/nano scales are introduced. The latest research progress on micro/nano-scaled mechanical metamaterials is also reviewed according to the type of materials. In addition, the structural and functional applications of micro/nano-scaled mechanical metamaterials are further summarized. Finally, the challenges, including advanced 3D printing technologies, novel material development, and innovative structural design, for micro/nano-scaled mechanical metamaterials are discussed, and future perspectives are provided. The review aims to provide insight into the research and development of 3D-printed micro/nano-scaled mechanical metamaterials.
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Affiliation(s)
- Ruyue Su
- State Key Laboratory of Explosion Science and Technology, Beijing Institute of Technology, Beijing, 100081, P. R. China
- Institute of Advanced Structure Technology, Beijing Institute of Technology, Beijing, 100081, P. R. China
| | - Jingyi Chen
- State Key Laboratory of Explosion Science and Technology, Beijing Institute of Technology, Beijing, 100081, P. R. China
- Institute of Advanced Structure Technology, Beijing Institute of Technology, Beijing, 100081, P. R. China
| | - Xueqin Zhang
- Institute of Advanced Structure Technology, Beijing Institute of Technology, Beijing, 100081, P. R. China
| | - Wenqing Wang
- Institute of Advanced Structure Technology, Beijing Institute of Technology, Beijing, 100081, P. R. China
| | - Ying Li
- State Key Laboratory of Explosion Science and Technology, Beijing Institute of Technology, Beijing, 100081, P. R. China
- Institute of Advanced Structure Technology, Beijing Institute of Technology, Beijing, 100081, P. R. China
| | - Rujie He
- State Key Laboratory of Explosion Science and Technology, Beijing Institute of Technology, Beijing, 100081, P. R. China
- Institute of Advanced Structure Technology, Beijing Institute of Technology, Beijing, 100081, P. R. China
| | - Daining Fang
- Institute of Advanced Structure Technology, Beijing Institute of Technology, Beijing, 100081, P. R. China
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Amini A, Guijt RM, Themelis T, De Vos J, Eeltink S. Recent developments in digital light processing 3D-printing techniques for microfluidic analytical devices. J Chromatogr A 2023; 1692:463842. [PMID: 36745962 DOI: 10.1016/j.chroma.2023.463842] [Citation(s) in RCA: 8] [Impact Index Per Article: 8.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/08/2022] [Revised: 01/19/2023] [Accepted: 01/30/2023] [Indexed: 02/04/2023]
Abstract
Digital light processing (DLP) 3D printing is rapidly advancing and has emerged as a powerful additive manufacturing approach to fabricate analytical microdevices. DLP 3D-printing utilizes a digital micromirror device to direct the projected light and photopolymerize a liquid resin, in a layer-by-layer approach. Advances in vat and lift design, projector technology, and resin composition, allow accurate fabrication of microchannel structures as small as 18 × 20 µm. This review describes the latest advances in DLP 3D-printing technology with respect to instrument set-up and resin formulation and highlights key efforts to fabricate microdevices targeting emerging (bio-)analytical chemistry applications, including colorimetric assays, extraction, and separation.
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Affiliation(s)
- Ali Amini
- Department of Chemical Engineering, Vrije Universiteit Brussel (VUB), Pleinlaan 2, Brussels B-1050, Belgium
| | - Rosanne M Guijt
- Centre for Regional and Rural Futures, Deakin University, Geelong, Australia
| | - Thomas Themelis
- Department of Chemical Engineering, Vrije Universiteit Brussel (VUB), Pleinlaan 2, Brussels B-1050, Belgium
| | - Jelle De Vos
- Department of Chemical Engineering, Vrije Universiteit Brussel (VUB), Pleinlaan 2, Brussels B-1050, Belgium
| | - Sebastiaan Eeltink
- Department of Chemical Engineering, Vrije Universiteit Brussel (VUB), Pleinlaan 2, Brussels B-1050, Belgium.
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Kim CK, Cho D, Kim S, Song SW, Seo KM, Cho YT. High-Throughput Metal 3D Printing Pen Enabled by a Continuous Molten Droplet Transfer. ADVANCED SCIENCE (WEINHEIM, BADEN-WURTTEMBERG, GERMANY) 2023; 10:e2205085. [PMID: 36526589 PMCID: PMC9951324 DOI: 10.1002/advs.202205085] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 09/05/2022] [Revised: 11/29/2022] [Indexed: 06/17/2023]
Abstract
In metal additive manufacturing (AM), arc plasma is attracting attention as an alternative heat source to expensive lasers to enable the use of various metal wire materials with a high deposition efficiency. However, the stepwise material deposition and resulting limited number of degrees of freedom limit their potential for high-throughput and large-scale production for industrial applications. Herein, a high-throughput metal 3D printing pen (M3DPen) strategy is proposed based on an arc plasma heat source by harnessing the surface tension of the molten metal for enabling continuous material deposition without a downward flow by gravity. The proposed approach differs from conventional arc-based metal AM in that it controls the solidification and cooling time between interlayers of a point-by-point deposition path, thereby allowing for continuous metal 3D printing of freestanding and overhanging structures at once. The resulting mechanical properties and unique microstructures by continuous metal deposition that occur due to the difference in the thermal conditions of the molten metal under cooling are also investigated. This technology can be applied to a wide range of alloy systems and industrial manufacturing, thereby providing new possibilities for metal 3D printing.
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Affiliation(s)
- Chan Kyu Kim
- Department of Mechanical EngineeringChangwon National University20, Changwondaehak‐ro, Uichang‐guChangwon‐siGyeongsangnam‐do51140Republic of Korea
- Department of Joining TechnologyMaterials Testing & Reliability DivisionKorea Institute of Materials Science797, Changwon‐daero, Seongsan‐guChangwon‐siGyeongsangnam‐do51508Republic of Korea
| | - Dae‐Won Cho
- Busan Machinery Research CenterKorea Institute of Machinery and Materials48, Mieumsandan 5–40, 41beon‐gil, Gangseo‐guBusan46744Republic of Korea
| | - Seok Kim
- Department of Mechanical EngineeringChangwon National University20, Changwondaehak‐ro, Uichang‐guChangwon‐siGyeongsangnam‐do51140Republic of Korea
| | - Sang Woo Song
- Department of Joining TechnologyMaterials Testing & Reliability DivisionKorea Institute of Materials Science797, Changwon‐daero, Seongsan‐guChangwon‐siGyeongsangnam‐do51508Republic of Korea
| | - Kang Myung Seo
- Department of Joining TechnologyMaterials Testing & Reliability DivisionKorea Institute of Materials Science797, Changwon‐daero, Seongsan‐guChangwon‐siGyeongsangnam‐do51508Republic of Korea
| | - Young Tae Cho
- Department of Mechanical EngineeringChangwon National University20, Changwondaehak‐ro, Uichang‐guChangwon‐siGyeongsangnam‐do51140Republic of Korea
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High-resolution 3D printing for healthcare. 3D Print Med 2023. [DOI: 10.1016/b978-0-323-89831-7.00013-4] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/28/2023] Open
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Hsiao K, Lee BJ, Samuelsen T, Lipkowitz G, Kronenfeld JM, Ilyn D, Shih A, Dulay MT, Tate L, Shaqfeh ESG, DeSimone JM. Single-digit-micrometer-resolution continuous liquid interface production. SCIENCE ADVANCES 2022; 8:eabq2846. [PMID: 36383664 PMCID: PMC9668307 DOI: 10.1126/sciadv.abq2846] [Citation(s) in RCA: 5] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 05/11/2022] [Accepted: 09/28/2022] [Indexed: 05/29/2023]
Abstract
To date, a compromise between resolution and print speed has rendered most high-resolution additive manufacturing technologies unscalable with limited applications. By combining a reduction lens optics system for single-digit-micrometer resolution, an in-line camera system for contrast-based sharpness optimization, and continuous liquid interface production (CLIP) technology for high scalability, we introduce a single-digit-micrometer-resolution CLIP-based 3D printer that can create millimeter-scale 3D prints with single-digit-micrometer-resolution features in just a few minutes. A simulation model is developed in parallel to probe the fundamental governing principles in optics, chemical kinetics, and mass transport in the 3D printing process. A print strategy with tunable parameters informed by the simulation model is adopted to achieve both the optimal resolution and the maximum print speed. Together, the high-resolution 3D CLIP printer has opened the door to various applications including, but not limited to, biomedical, MEMS, and microelectronics.
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Affiliation(s)
- Kaiwen Hsiao
- Department of Radiology, Stanford University, Stanford, CA 94305, USA
| | - Brian J. Lee
- Department of Radiology, Stanford University, Stanford, CA 94305, USA
- Department of Mechanical Engineering, Sungkyunkwan University, Suwon, Republic of Korea
| | - Tim Samuelsen
- Department of Mechanical Engineering, Stanford University, Stanford, CA 94305, USA
| | - Gabriel Lipkowitz
- Department of Mechanical Engineering, Stanford University, Stanford, CA 94305, USA
| | | | - Dan Ilyn
- Department of Mechanical Engineering, Stanford University, Stanford, CA 94305, USA
| | - Audrey Shih
- Department of Chemical Engineering, Stanford University, Stanford, CA 94305, USA
| | - Maria T. Dulay
- Department of Radiology, Stanford University, Stanford, CA 94305, USA
| | - Lee Tate
- Digital Light Innovations, Austin, TX 78728, USA
| | - Eric S. G. Shaqfeh
- Department of Mechanical Engineering, Stanford University, Stanford, CA 94305, USA
- Department of Chemical Engineering, Stanford University, Stanford, CA 94305, USA
| | - Joseph M. DeSimone
- Department of Radiology, Stanford University, Stanford, CA 94305, USA
- Department of Chemical Engineering, Stanford University, Stanford, CA 94305, USA
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Improvement of the Geometric Accuracy for Microstructures by Projection Stereolithography Additive Manufacturing. CRYSTALS 2022. [DOI: 10.3390/cryst12060819] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
Abstract
Projection stereolithography creates 3D structures by projecting patterns onto the surface of a photosensitive material layer by layer. Benefiting from high efficiency and resolution, projection stereolithography 3D printing has been widely used to fabricate microstructures. To improve the geometric accuracy of projection stereolithography 3D printing for microstructures, a compensation method based on structure optimization is proposed according to mathematical analysis and simulation tests. The performance of the proposed compensation method is verified both by the simulation and the 3D printing experiments. The results indicate that the proposed compensation method is able to significantly improve the shape accuracy and reduce the error of the feature size. The proposed compensation method is also proved to improve the dimension accuracy by 21.7%, 16.5% and 19.6% for the circular, square and triangular bosses respectively. While the improvements on the dimension accuracy by 16%, 17.6% and 13.8% for the circular, square and triangular holes are achieved with the proposed compensation method. This work is expected to provide a method to improve the geometric accuracy for 3D printing microstructures by projection stereolithography.
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Numerical Study of the Thermal and Fluid Behavior of Three-Dimensional Microstructures for Efficient Catalytic Converters. ENERGIES 2022. [DOI: 10.3390/en15124200] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/10/2022]
Abstract
Global regulations for emission reduction are continually becoming stricter, and conventional catalytic converters may be efficient in the future because of their low conversion efficiencies at cold-start. In this study, to overcome the performance limitations of conventional catalytic converters, a three-dimensional (3D) microstructured catalytic substrate was designed, and simulations of the fluid flow, heat transfer, and chemical reaction for the proposed catalytic substrates were performed using computational fluid dynamics (CFD) analysis. The effect of the pressure drop on the catalytic conversion efficiency of various 3D microarchitectures was investigated. Due to the three-dimensional microstructure, the fluid flow changed and fluid pressure increased, which led to energy loss. It was confirmed that the abrupt change in flow increased the heat transfer. The findings showed that the fluid flow changed due to the existence of a complex periodic microlattice structure instead of the existing monolithic structure, which promoted the conversion of harmful substances. Based on the CFD analysis of the thermal and fluid properties, it was confirmed that 3D microarchitectures can provide alternatives to conventional catalytic supports structures for efficient catalytic converters.
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Low Heat Capacity 3D Hollow Microarchitected Reactors for Thermal and Fluid Applications. ENERGIES 2022. [DOI: 10.3390/en15114073] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
Abstract
Lightweight reactor materials that simultaneously possess low heat capacity and large surface area are desirable for various applications such as catalytic supports, heat exchangers, and biological scaffolds. However, they are challenging to satisfy this criterion originating from their structural property in most porous cellular solids. Microlattices have great potential to resolve this issue in directing transport phenomena because of their hierarchically ordered design and controllable geometrical features such as porosity, specific surface, and tortuosity. In this study, we report hollow ceramic microlattices comprising a 10 μm thick hollow nickel oxide beam in an octet-truss architecture with low heat capacity and high specific surface area. Our microarchitected reactors exhibited a low heat capacity for a rapid thermal response with a small Biot number (Bi << 1) and large intertwined surface area for homogeneous flow mixing and chemical reactions, which made them ideal candidates for various energy applications. The hollow ceramic microlattice was fabricated by digital light three-dimensional (3D) printing, composite electroless plating, polymer removal, and subsequent thermal annealing. The transient thermal response and fluidic properties of the 3D-printed microstructures were experimentally investigated using a small-scale thermal and fluid test system, and analytically interpreted using simplified models. Our findings indicate that hollow microarchitected reactors provide a promising platform for developing multifunctional materials for thermal and fluid applications.
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