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Ultrafast 3D printing with submicrometer features using electrostatic jet deflection.

ABSTRACT: Additive manufacturing technologies based on layer-by-layer deposition of material ejected from a nozzle provide unmatched versatility but are limited in terms of printing speed and resolution. Electrohydrodynamic jetting uniquely allows generating submicrometer jets that can reach speeds above 1?m?s-1, but such jets cannot be precisely collected by too slow mechanical stages. Here, we demonstrate that controlling the voltage applied to electrodes located around the jet, its trajectory can be continuously adjusted with lateral accelerations up to 106?m?s-2. Through electrostatically deflecting the jet, 3D objects with submicrometer features can be printed by stacking nanofibers on top of each other at layer-by-layer frequencies as high as 2000 Hz. The fast jet speed and large layer-by-layer frequencies achieved translate into printing speeds up to 0.5?m?s-1 in-plane and 0.4?mm?s-1 in the vertical direction, three to four orders of magnitude faster than techniques providing equivalent feature sizes.

SUBMITTER: Liashenko I

PROVIDER: S-EPMC7005155 | biostudies-literature | 2020 Feb

REPOSITORIES: biostudies-literature

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Ultrafast 3D printing with submicrometer features using electrostatic jet deflection.

Liashenko Ievgenii I Rosell-Llompart Joan J Cabot Andreu A

Nature communications 20200206 1

Additive manufacturing technologies based on layer-by-layer deposition of material ejected from a nozzle provide unmatched versatility but are limited in terms of printing speed and resolution. Electrohydrodynamic jetting uniquely allows generating submicrometer jets that can reach speeds above 1 m s<sup>-1</sup>, but such jets cannot be precisely collected by too slow mechanical stages. Here, we demonstrate that controlling the voltage applied to electrodes located around the jet, its trajector ...[more]

PMID: 32029714

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Project description:Additive manufacturing promises to revolutionize manufacturing industries. However, 3D printing of novel build materials is currently limited by constraints inherent to printer designs. In this work, a bench-top powder melt extrusion (PME) 3D printer head was designed and fabricated to print parts directly from powder-based materials rather than filament. The final design of the PME printer head evolved from the Rich Rap Universal Pellet Extruder (RRUPE) design and was realized through an iterative approach. The PME printer was made possible by modifications to the funnel shape, pressure applied to the extrudate by the auger, and hot end structure. Through comparison of parts printed with the PME printer with those from a commercially available fused filament fabrication (FFF) 3D printer using common thermoplastics poly(lactide) (PLA), high impact poly (styrene) (HIPS), and acrylonitrile butadiene styrene (ABS) powders (< 1 mm in diameter), evaluation of the printer performance was performed. For each build material, the PME printed objects show comparable viscoelastic properties by dynamic mechanical analysis (DMA) to those of the FFF objects. However, due to a significant difference in printer resolution between PME (X-Y resolution of 0.8 mm and a Z-layer height calibrated to 0.1 mm) and FFF (X-Y resolution of 0.4 mm and a Z-layer height of 0.18 mm), as well as, an inherently more inconsistent feed of build material for PME than FFF, the resulting print quality, determined by a dimensional analysis and surface roughness comparisons, of the PME printed objects was lower than that of the FFF printed parts based on the print layer uniformity and structure. Further, due to the poorer print resolution and inherent inconsistent build material feed of the PME, the bulk tensile strength and Young's moduli of the objects printed by PME were lower and more inconsistent (49.2 ± 10.7 MPa and 1620 ± 375 MPa, respectively) than those of FFF printed objects (57.7 ± 2.31 MPa and 2160 ± 179 MPa, respectively). Nevertheless, PME print methods promise an opportunity to provide a platform on which it is possible to rapidly prototype a myriad of thermoplastic materials for 3D printing.

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Ultrafast 3D printing with submicrometer features using electrostatic jet deflection.

Publications

Ultrafast 3D printing with submicrometer features using electrostatic jet deflection.

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