A Binder Jet Printed, Stainless Steel Preconcentrator as an In-Line Injector of Volatile Organic Compounds

Additively manufactured, long, serpentine submillimeter channels by combining binder jet printing and liquid-phase sintering

Metallic microfluidic devices made from powder-bed additive manufacturing systems have received increasing attention, but their feasible channel geometry and complexity are often limited by lack of an effective approach to removing trapped powder particles within the channels or conduits of the sintered parts. Here, we present an innovative approach to fabricating long serpentine, high-aspect-ratio submillimeter channels made of stainless steel 316L (SS) by binder jet printing (BJP) and liquid-phase sintering. We leverage the unique nature of the BJP process, that is printing and consolidation steps are decoupled, enabling us to join two or more parts during the sintering step. Instead of constructing the channel device as a single part, we print multiple parts for easy powder removal and later join them to form enclosed channels. The key innovation lies in adding sintering additives like boron nitrides (BN) to the SS stock powder-at the SS/BN interfaces, liquid phase is locally generated at temperature much lower than the SS melting temperature, facilitating the bonding of the multiple parts as well as the consolidation of parts for near-full density. We systematically vary the sintering temperature to show how it affects the joining quality and the channel shape distortion. The joining quality such as the fracture strengths of the joined samples is measured by a pull test while the shape distortion is characterized by various imaging techniques. The feasibility of the proposed approach is demonstrated by fabricating a 400-mm-long, fully enclosed serpentine channel with a rectangular cross-section of 0.5 mm in width and 1.8 mm in height. The pressure drop across this 3D-printed SS serpentine channels is measured for air flow and compared to a standard gas flow model, showing that the device is free of leakage or clogs.

Densification and Properties of Bimodal 316L Stainless Steel Produced by Binder Jetting Printing with Addition of B4C

Boron-based aids are commonly introduced to tackle the unsatisfactory densification of SS316L parts fabricated by binder jetting (BJ) technology. However, there is scarce study on the effect of sintering aids on the mechanical performance. This work investigates the effect of B4C aids and sintering temperature on the mechanical performance and microscopic morphology of BJ printing SS316L parts. SS316L powders with a bimodal size distribution were adopted to enhance density and reduce the shape distortion. Besides, B4C was added as a sintering aid to promote densification during sintering. The results show that the bimodal powder is in favour of the density increase and the sintering process. The sintering temperature is largely reduced with the addition of B4C. Further, the mechanical performance is mainly affected by the final density and B4C content. In view of a comprehensive evaluation of shape retention and properties, B4C content of 1 wt.% and sintering temperature of 1250°C are expected to be the optimal parameters.

Programmable and Modularized Gas Sensor Integrated by 3D Printing

The rapid advancement of intelligent manufacturing technology has enabled electronic equipment to achieve synergistic design and programmable optimization through computer-aided engineering. Three-dimensional (3D) printing, with the unique characteristics of near-net-shape forming and mold-free fabrication, serves as an effective medium for the materialization of digital designs into usable devices. This methodology is particularly applicable to gas sensors, where performance can be collaboratively optimized by the tailored design of each internal module including composition, microstructure, and architecture. Meanwhile, diverse 3D printing technologies can realize modularized fabrication according to the application requirements. The integration of artificial intelligence software systems further facilitates the output of precise and dependable signals. Simultaneously, the self-learning capabilities of the system also promote programmable optimization for the hardware, fostering continuous improvement of gas sensors for dynamic environments. This review investigates the latest studies on 3D-printed gas sensor devices and relevant components, elucidating the technical features and advantages of different 3D printing processes. A general testing framework for the performance evaluation of customized gas sensors is proposed. Additionally, it highlights the superiority and challenges of programmable and modularized gas sensors, providing a comprehensive reference for material adjustments, structure design, and process modifications for advanced gas sensor devices.

Micropreconcentrators: Recent Progress in Designs and Applications

The detection of chemicals is a fundamental issue of modern civilisation, however existing methods do not always achieve the desired sensitivity. Preconcentrators, which are devices that allow increasing the concentration of the intended analyte via e.g., adsorption/desorption, are one of the solutions for increasing the sensitivity of chemical detection. The increased detection sensitivity granted by preconcentration can be used to miniaturise detection instruments, granting them portability. The primary goal of this review is to report on and briefly explain the most relevant recent developments related to the design and applications of preconcentrators. The key design elements of preconcentrators and the emerging area of liquid-phase preconcentrators are briefly discussed, with the most significant applications of these devices being highlighted.

3D printing in analytical chemistry: current state and future

The rapid development of additive technologies in recent years is accompanied by their intensive introduction into various fields of science and related technologies, including analytical chemistry. The use of 3D printing in analytical instrumentation, in particular, for making prototypes of new equipment and manufacturing parts having complex internal spatial configuration, has been proved as exceptionally effective. Additional opportunities for the widespread introduction of 3D printing technologies are associated with the development of new optically transparent, current- and thermo-conductive materials, various composite materials with desired properties, as well as possibilities for printing with the simultaneous combination of several materials in one product. This review will focus on the application of 3D printing for production of new advanced analytical devices, such as compact chromatographic columns for high performance liquid chromatography, flow reactors and flow cells for detectors, devices for passive concentration of toxic compounds and various integrated devices that allow significant improvements in chemical analysis. A special attention is paid to the complexity and functionality of 3D-printed devices.

3D Printed MEMS Technology-Recent Developments and Applications

Microelectromechanical systems (MEMS) are of high interest for recent electronic applications. Their applications range from medicine to measurement technology, from microfluidics to the Internet of Things (IoT). In many cases, MEMS elements serve as sensors or actuators, e.g., in recent mobile phones, but also in future autonomously driving cars. Most MEMS elements are based on silicon, which is not deformed plastically under a load, as opposed to metals. While highly sophisticated solutions were already found for diverse MEMS sensors, actuators, and other elements, MEMS fabrication is less standardized than pure microelectronics, which sometimes blocks new ideas. One of the possibilities to overcome this problem may be the 3D printing approach. While most 3D printing technologies do not offer sufficient resolution for MEMS production, and many of the common 3D printing materials cannot be used for this application, there are still niches in which the 3D printing of MEMS enables producing new structures and thus creating elements for new applications, or the faster and less expensive production of common systems. Here, we give an overview of the most recent developments and applications in 3D printing of MEMS.

Gas Detection Using Portable Deep-UV Absorption Spectrophotometry: A Review

Several gas molecules of environmental and domestic significance exhibit a strong deep-UV absorption. Therefore, a sensitive and a selective gas detector based on this unique molecular property (i.e., absorption at a specific wavelength) can be developed using deep-UV absorption spectrophotometry. UV absorption spectrometry provides a highly sensitive, reliable, self-referenced, and selective approach for gas sensing. This review article addresses the recent progress in the application of deep-UV absorption for gas sensing owing to its inherent features and tremendous potentials. Applications, advancements, and challenges related to UV emission sources, gas cells, and UV photodetectors are assessed and compared. We present the relevant theoretical aspects and challenges associated with the development of portable sensitive spectrophotometer. Finally, the applications of UV absorption spectrometry for ozone, NO₂, SO₂, and aromatic organic compounds during the last decades are discussed and compared. A portable UV absorption spectrophotometer can be developed by using LEDs, hollow core waveguides (HCW), and UV photodetectors (i.e., photodiodes). LED provides a portable UV emission source with low power input, low-intensity drifts, low cost, and ease of alignment. It is a quasi-chromatic UV source and covers the absorption band of molecules without optical filters for absorbance measurement of a target analyte. HCWs can be applied as a miniature gas cell for guiding UV radiation for measurement of low gas concentrations. Photodiodes, on the other hand, offer a portable UV photodetector with excellent spectral selectivity with visible rejection, minimal dark current, linearity, and resistance against UV-aging.