Materials. Design. ΚενοΤομια. Processing/ Manufacturing

Transcription

1 Materials Design ΚενοΤομια Processing/ Manufacturing

2 3D printing

3 From Concept, to Prototyping, to Production The Prototyping Process Can Be Long & Costly RAPID PROTOTYPING

4 Using the power of the Internet, it may eventually be possible to send a blueprint of any product to any place in the world to be replicated by a 3D printer with "elemental inks" capable of being combined into any material substance of any desired form.

5 Manufacturing The Pyramids (~2500 B.C.) Captain Hook

6 Subtractive vs Additive Manufacturing

7 Which to choose? Cost is critical e.g. CNC machining, Molding, etc. Q: Where CNC machining stands? CNC: Computerized Numerical Control

8 Additive Manufacturing (ΑΜ) (or 3D Printing ) Why so much hype?

9 3D Printing Technologies * * * * Vat: καδος, δεξαμενη

10

11 Resin: Some Material Definitions Viscous Treatment Solid A natural or synthetic compound that begins in a highly viscous state and hardens with treatment. Thermoplastic: A polymer that becomes pliable or moldable above a specific temperature and solidifies upon cooling Photo-curable: Viscous Light (UV) Solid

12 Glass Transition Temperature, T g (most) Polymers can exist in 2 states:

13 3D Printing: 4 ways CONCEPT: Material is FORMED or ADDED For an overview, read more:

14 Fused Deposition Modeling (FDM)* CONCEPT: a plastic filament or metal wire is heated to its melting point and unwound from a coil. Heated Bed (~100 0 C) *trademarked & commercialized in 1990 by Stratasys Inc *best-selling rapid prototyping technology

15 FDM 3D printer in Action

16 Materials for FDM ABS PLA

17 FDM Biocompatible Materials PC-ISO = PolyCarbonate-ISO

18 Selective Laser Sintering (SLS) CONCEPT: Use of laser as the power source to sinter powdered material Used for plastics, ceramics, glass, metals, composites Need a binder Sintering: συντηξη Materials: any material that can be in powder form. Most common: nylon, glass-filled nylon, polystyrene, steel, titanium, alloy mixtures.

19 SLS in action

20 StereoLithography (SLA) Concept: Focus an ultraviolet (UV) laser on to a vat of photopolymer resin. ies/stereolithography.html Advantage: Speed Disadvantage: cost of the resin and of the machine

21 SLA and Materials

22 Σχετικο- Ασχετο: Inject Printing (2D) The nozzle /famous_mems_products.htm

23 Polyjet 3D Printing Concept: layers of liquid photopolymer are injected on a build tray and cured instantly with UV light Jetting Heads (one for the photopolymer and one for the support)

24 Polyjet in Action

25 Materials for Polyjet Printing Nearly 1,000 composite materials with specific, predictable properties - by blending two or three base resins.

26 Polyjet 3D Printing of Bio-compatible Materials

27 Which One to use? HOME APPLICA TIONS INDUSTRY APPLICATI ONS Table taken from:

28 Some Numbers

29 Q: Can you 3D print Metals? YES! Selective Laser Sintering Watch at: Titanium Glasses The titanium implant has a large number of cavities. These weightreducing recesses in otherwise solid parts can only be achieved through Additive Manufacturing.

30 Q: Can you 3D Print Wood? YES! Selective Laser Sintering rough surface with a granular feel

31 3D printing: Applications in Medical Field

32 Story I: Rebuilding a face Q: could you make the implant not using 3D printing?

33 Story II: 3D-Airway Printed Splint The Problem: Tracheomalacia in babies occurs when cartilage in the trachea develops abnormally the tracheal walls collapse. The CT scan The 3D printed parts Watch the Story:

34 Story III: 3D-printed Vertebra (σπονδυλος) The Problem: A rare bone cancer can grow in the vertebra A normal spine model The traditional Titanium Tube 3D-printed artificial Vertebra Vertebra made out of titanium powder: the material most orthopedic implants are made from because it's biocompatible, light, and strong. The titanium replacement bone is filled with tiny pores that will allow real bone to naturally grow through it.

35 Story 4: Scaffolds for Tissue Engineering Left to right: Sheep meniscus; 3-D model of meniscus obtained from laser scanning; 3-D printed anatomically correct meniscus scaffold

36 3D Bio-Printing (or Tissue Engineering Meets 3D-Printing )

37 Evolution of Tissue Engineering 3D Bio-Printing

38 3D-Printing of Biomaterials

39 Printing a Vessel 3D print of a complex cardiovascular system ts-can-now-3d-print-working-bloodvessels/

40 3D Print Skin Cells Onto Burn Wounds 3d scanning the wound Printing first layer of skin cells The Process: The laser scans the patient's burn and that information gets translated into a personalized plan for filling the wound up with cells. Then the inkjet printer lays down the cells individually, one layer at a time until the burned area is completely covered Printing second layer of skin cells

41 Moving Forward: Functional Organs 3D-printing hydrogels impregnated with living chondrocyte cells those found in healthy cartilage. As well as printing the hydrogels and cells, a third ink containing nanosized conducting silver was added, and a coiled antenna printed in a specific site in the middle. These ears could pick up a range of frequencies much broader than non-bionic human ears can manage

42 Direct Laser Writing for cells Acceptor Substrate Taken from: Laser Direct-Write Techniques for Printing of Complex Materials

43 3D Printing in the Micro/Nano Scale

44 MicroStereoLithography (msl) Concept: Photopattern a photosensitive polymer layer by layer to create a 3D structure You need: A liquid UV-curable Photopolymer A UV Laser A xyz Scanning System How: A UV light beam patterns the surface of a photopolymer layer by layer, causing polymerization or crosslinking After patterning, parts are cleaned by immersion in a chemical bath and then cured in a UV oven. Lateral Resolution: > 2 microns (depends on the depth)

45 Applications of msl Fun Tissue Engineering

46 Dip-Pen NanoLithography (DPN) Principle: The tip of a microscopic cantilever, coated with an ink, deposits ( writes ) a material on a substrate Tip Molecular Ink Specifications Resolution: 50 nm 10 mm Material That Can Be Deposited Molecular Inks: Alkane thiols, Silanes Liquid Inks: Proteins, Peptides, DNA, Hydrogels Liquid Inks DPN is a scanning probe technique that originated from Atomic Force Microscopy

47 Variations of DPN A. Thermal DPN B. Electro PN Solid Ink Heated cantilever C. Nano Fountain Pen

48 DPN Nanoarrays to Detect Viruses ADNANTAGES Nanoarrays can hold more features than conventional microarrays Decreased sample volumes Detection of a smaller number of target molecules for a given analyte concentration (lower limit of detection) DISADNANTAGES? Reade More at: Applications of dip-pen nanolithography, Nature nanotechnology VOL 2 MARCH 2007