Current technologies and advances in additive manufacturing Dr. Ehab Saleh 28/09/2017
Content Centre for Additive Manufacturing (CfAM) Hype cycle of technologies and 3D printing Current additive manufacturing technologies Advances in additive manufacturing Conclusion
Centre for Additive Manufacturing (CfAM) A group established in 1992 focussing on RP & RT. Started AM research in 2000. Over 120 staff and postgrad dedicated to AM research. Currently have vacancies for post-docs and PhD students (10 per year). Research facilities worth over $12 million.
Centre for Additive Manufacturing - Equipment Polymer Powder Polymer Jetting Metallic Powder Polymer Filament Nano-scale
Centre for Additive Manufacturing Recent Additions JetX Multi-Material (6) printer 250 x 250 x 200 mm envelope Nanoscribe Professional GT < 200 nm feature resolution up to 100x100mm envelope MetalJet multi-material high temperature 4-head system
Technologies hype cycle
Technologies hype cycle
Technologies hype cycle
Technologies hype cycle
Technologies hype cycle established the challenge
Technologies hype cycle established the challenge
3D printing hype cycle
Current AM technologies Many acronyms : FDM, SLM, SLS, SLA, SPJ, DED, BMD, EBM, EBAM
Current AM technologies Many acronyms : FDM, SLM, SLS, SLA, SPJ, DED, BMD, EBM, EBAM
Current AM technologies Photopolymerisation
Current AM technologies Photopolymerisation Stereolithography (SLA)
Current AM technologies Photopolymerisation Stereolithography (SLA) Materials: Photo-curable resins and composites
Current AM technologies Powder bed fusion
Current AM technologies Powder bed fusion
Current AM technologies Powder bed fusion Selective Laser Melting (SLM)
Current AM technologies Powder bed fusion Selective Laser Melting (SLM) Materials: Steel, titanium, aluminium, cobalt-chrome and nickel
Current AM technologies Powder bed fusion Selective Laser Sintering (SLS)
Current AM technologies Powder bed fusion Selective Laser Sintering (SLS) Materials: Polymers Nylon
Advances of AM
Advances of AM Material Jetting (MJ)
Advances of AM Material Jetting (MJ) Fundamentally scalable Droplet on Demand (DoD) Multi-material printing
"3D inkjet-printed UV-curable inks for multi-functional electromagnetic applications", Addit. Manuf. 2016, V 13, p143-148 Advances of AM Material Jetting (MJ) Inkjet printing of electromagnetic responsive inks UV curable doped-active ink was printed alongside polymeric ink.
Advances of AM Material Jetting (MJ) Multifunctional additive manufacturing (MFAM) Dissimilar materials can be deposited alongside each other (metal-polymer).
Advances of AM Material Jetting (MJ) Multifunctional additive manufacturing (MFAM) Dissimilar materials can be deposited alongside each other (metal-polymer). Ink solidification requirements can be challenging.
Advances of AM Material Jetting (MJ) Multifunctional additive manufacturing (MFAM) Dissimilar materials can be deposited alongside each other (metal-polymer). Ink solidification requirements can be challenging. Recent breakthrough used a single UV energy source to solidify conductive and polymeric inks in a single structure. 3D Inkjet Printing of Electronics Using UV Conversion, 2017, Advanced Materials Technologies, 1700134
Advances of AM Material Jetting (MJ) Reactive jetting (RJ) Two materials are jetting on top of each other to react and polymerise Epoxies, PDMS, Polyurethane
Advances of AM Material Jetting (MJ) Hotmelt jetting (HMJ) Usually waxes are inkjet-printed from a heated reservoir.
Advances of AM Material Jetting (MJ) Hotmelt jetting (HMJ) Usually waxes are inkjet-printed from a heated reservoir. "3D inkjet printing of tablets exploiting bespoke complex geometries for controlled and tunable drug release" J Controlled Release. 2017;261:207 215
Advances of AM Material Jetting (MJ) High viscosity jetting (HVJ) Up to 15000 cp, widens the material selection.. PicoPulse printhead
Advances of AM Material Jetting (MJ) High viscosity jetting (HVJ) Up to 15000 cp, widens the material selection.. "High Viscosity Jetting of Conductive and Dielectric Pastes for Printed Electronics" Proceedings of SFF Symposium, Austin TX USA (2015), pp. 40-55 PicoPulse printhead
Advances of AM Material Jetting (MJ) Inkjet printing and rapid reduction of graphene oxide Graphene oxide is very stable for ink formulation Usually requires high temperatures or various chemicals steps to reduce. GO before reduction After 1 minute of reduction!!
Advances of AM Material Jetting (MJ) Inkjet printing and rapid reduction of graphene oxide Graphene oxide is very stable for ink formulation Usually requires high temperatures or various chemicals steps to reduce.
Advances of AM Material Jetting (MJ) Inkjet printing and rapid reduction of graphene oxide
Advances of AM Material Jetting (MJ) Inkjet printing and rapid reduction of graphene oxide - FET
Advances of AM Material Jetting (MJ) Inkjet printing and rapid reduction of graphene oxide suspended Potential application: ultrasound sensing.
Advances of AM THz applications 3D printing can provide excellent resolution to facilitate THz applications. Lenses, cavities and various components could be potential targets. "A 3-D Printed Lightweight X-Band Waveguide Filter Based on Spherical Resonators", IEEE Microwave and wireless components letters, Vol. 25, No. 7, July 2015
Desktop metal 3D printer Two versions: FDM based to extrude metal-binder paste to produce green parts.
Desktop metal 3D printer Two versions: FDM based to extrude metal-binder paste to produce green parts. Binder jetting based, to jet a binder over metal powder to produce green parts.
Advances of AM Photopolymerisation Carbon3D CLIP technology - fast Photocentric 3D day light resin - inexpensive Carbon3D Liquid Crystal
Conclusions 3D printing is getting there to fulfil the vision that was anticipated during the hype.
Questions Ehab Saleh ehab.saleh@nottingham.ac.uk EPSRC 2014 photo competition winner