A new approach for ultrarapid 3D manufacturing creates complex aperiodic volumes in a single step.

The inner nacreous layer of gastropod mollusc Trochus niloticus is composed of ∼95 wt% planar arrays of polygonal aragonite-based tablets (∼8 μm wide, ∼0.9 μm thick, stacked ∼40 nm apart) and ∼5 wt% biomacromolecules. High-resolution tapping mode atomic force microscope images enabled nanoscale resolution of fractured tablet cross-sections, the organic component, and deformation of individual nanoasperities on top of tablet surfaces. Nanoindentation was performed on individual nacre tablets and the elastic modulus E and yield stress σy were reduced from elastic-plastic finite element simulations yielding E = 92 GPa, σy = 11 GPa (freshly cleaved samples) and E = 79 GPa, σy = 9 GPa (artificial seawater soaked samples). Images of the indents revealed extensive plastic deformation with a clear residual indent and surrounding pileup.

Early examples of computers were almost exclusively based on mechanical devices. Although electronic computers became dominant in the past 60 years, recent advancements in three-dimensional micro-additive manufacturing technology provide new fabrication techniques for complex microstructures which have rekindled research interest in mechanical computations. Here we propose a new digital mechanical computation approach based on additively-manufacturable micro-mechanical logic gates. The proposed mechanical logic gates (i.e., NOT, AND, OR, NAND, and NOR gates) utilize multi-stable micro-flexures that buckle to perform Boolean computations based purely on mechanical forces and displacements with no electronic components. A key benefit of the proposed approach is that such systems can be additively fabricated as embedded parts of microarchitected metamaterials that are capable of interacting mechanically with their surrounding environment while processing and storing digital data internally without requiring electric power.

No abstract

An error occurred while printing this article in the September issue of the Journal of Materials Research.

No abstract

Two-photon polymerization (TPP) is a laser writing process that enables fabrication of millimeter scale three-dimensional (3D) structures with submicron features. In TPP, writing is achieved via nonlinear two-photon absorption that occurs at high laser intensities. Thus, it is essential to carefully select the incident power to prevent laser damage during polymerization. Currently, the feasible range of laser power is identified by writing small test patterns at varying power levels. Herein, we demonstrate that the results of these tests cannot be generalized, because the damage threshold power depends on the proximity of features and reduces by as much as 47% for overlapping features. We have identified that this reduction occurs primarily due to an increase in the single-photon absorptivity of the resin after curing. We have captured the damage from proximity effects via X-ray 3D computed tomography (CT) images of a nonhomogenous part that has varying feature density. Part damage manifests as internal spherical voids that arise due to boiling of the resist. We have empirically quantified this proximity effect by identifying the damage threshold power at different writing speeds and feature overlap spacings. In addition, we present a first-order analytical model that captures the scaling of this proximity effect. Based on this model and the experiments, we have identified that the proximity effect is more significant at high writing speeds; therefore, it adversely affects the scalability of manufacturing. The scaling laws and the empirical data generated here can be used to select the appropriate TPP writing parameters.

No abstract