3D-printed in-line and out-of-plane layers with stimuli-responsive intelligence

Ravichandran, Dharneedar; Kakarla, Mounika; Xu, Weiheng; Jambhulkar, Sayli; Zhu, Yuxiang; Bawareth, Mohammed; Fonseca, Nathan; Patil, Dhanush; Song, Kenan

doi:10.1016/j.compositesb.2022.110352

Cited by 14 publications

(12 citation statements)

References 56 publications

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“…The MDIW (Figure c) nozzle extrudes stacks of even, parallel layers orders of magnitude thinner than the die’s outlet diameter, which impart additional capabilities to printed parts. These fine-layered filaments have been formed into parts that are both magnetically and thermally responsive. , Thermoplastic poly(urethane) (TPU) was mixed with iron oxide nanoparticles in one ink to impart a magnetic field response and mixed with poly(caprolactone) in the other ink to impart a thermal response. Therefore, these parts had both shape memory, unrolling or unfolding in response to heating, and anisotropic magnetization properties, orienting macroscopically in different directions in response to an applied magnetic field.…”

Section: Static Mixers and Forced Assembly: Multiplying Layersmentioning

confidence: 99%

Nozzle Innovations That Improve Capacity and Capabilities of Multimaterial Additive Manufacturing

McCauley,

Bayles

2024

ACS Eng. Au

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Multimaterial additive manufacturing incorporates multiple species within a single 3D-printed object to enhance its material properties and functionality. This technology could play a key role in distributed manufacturing. However, conventional layer-by-layer construction methods must operate at low volumetric throughputs to maintain fine feature resolution. One approach to overcome this challenge and increase production capacity is to structure multimaterial components in the printhead prior to deposition. Here we survey four classes of multimaterial nozzle innovations, nozzle arrays, coextruders, static mixers, and advective assemblers, designed for this purpose. Additionally, each design offers unique capabilities that provide benefits associated with accessible architectures, interfacial adhesion, material properties, and even living-cell viability. Accessing these benefits requires trade-offs, which may be mitigated with future investigation. Leveraging decades of research and development of multiphase extrusion equipment can help us engineer the next generation of 3D-printing nozzles and expand the capabilities and practical reach of multimaterial additive manufacturing.

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Section: Static Mixers and Forced Assembly: Multiplying Layersmentioning

confidence: 99%

Nozzle Innovations That Improve Capacity and Capabilities of Multimaterial Additive Manufacturing

McCauley,

Bayles

2024

ACS Eng. Au

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“…AM of intelligent/innovative dynamic structures, i.e., 4D printing, has primarily been composed of shape memory alloys (SMAs) and shape memory polymers (SMPs), which are smart materials capable of changing size, shape, or color under the influence of external stimuli (i.e., pressure, heat, light, water, pH, electrical or magnetic fields). [209][210][211] The potential applications of 4D printing are diverse and include self-assembling robots, medical implants that can adapt to the body's changing conditions, and building structures that can adjust to changing environmental conditions. For example, 3D printable PLA inks as SMP from direct writing retained excellent shape after UV-curing (Figure 15a 1 ) with thermal responsiveness.…”

Section: Diversify Device Intelligence Via 4d Printingmentioning

confidence: 99%

3D Printing‐Enabled Design and Manufacturing Strategies for Batteries: A Review

Fonseca,

Thummalapalli,

Jambhulkar

et al. 2023

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Lithium‐ion batteries (LIBs) have significantly impacted the daily lives, finding broad applications in various industries such as consumer electronics, electric vehicles, medical devices, aerospace, and power tools. However, they still face issues (i.e., safety due to dendrite propagation, manufacturing cost, random porosities, and basic & planar geometries) that hinder their widespread applications as the demand for LIBs rapidly increases in all sectors due to their high energy and power density values compared to other batteries. Additive manufacturing (AM) is a promising technique for creating precise and programmable structures in energy storage devices. This review first summarizes light, filament, powder, and jetting‐based 3D printing methods with the status on current trends and limitations for each AM technology. The paper also delves into 3D printing‐enabled electrodes (both anodes and cathodes) and solid‐state electrolytes for LIBs, emphasizing the current state‐of‐the‐art materials, manufacturing methods, and properties/performance. Additionally, the current challenges in the AM for electrochemical energy storage (EES) applications, including limited materials, low processing precision, codesign/comanufacturing concepts for complete battery printing, machine learning (ML)/artificial intelligence (AI) for processing optimization and data analysis, environmental risks, and the potential of 4D printing in advanced battery applications, are also presented.

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“…DIW excels in constructing structures with intricate geometries, showcasing proficiency in creating overhangs and internal voids. This capability makes it particularly suitable for generating specialized structures such as lattices, interwoven designs, or meta-structures, especially in biomedical applications. − …”

Section: Introductionmentioning

confidence: 99%

Ink-Based Additive Manufacturing of a Polymer/Coal Composite: A Non-Traditional Reinforcement

Sundaravadivelan,

Ravichandran,

Dmochowska

et al. 2024

ACS Appl. Eng. Mater.

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Coal, a crucial natural resource traditionally employed for generating carbonrich materials and powering global industries, has faced escalating scrutiny due to its adverse environmental impacts outweighing its utility in the contemporary world. In response to the worldwide shift toward sustainability, the United States alone has witnessed an approximate 50% reduction in coal consumption. Nevertheless, the ample availability of coal has spurred interest in identifying alternative sustainable applications. This research delves into the feasibility of utilizing coal as a nonconventional carbon-rich reinforcement in direct ink writing (DIW)-based 3D printing techniques. Our investigation here involves a thermosetting resin serving as a matrix, incorporating pulverized coal (250 μm in size) and carbon black as the reinforcement and a viscosity modifier, respectively. The ink formulation is meticulously designed to exhibit shear-thinning behavior essential for DIW 3D printing, ensuring uniform and continuous printing. Mechanical properties are assessed through the 3D printing of ASTM standard specimens to validate the reinforcing impact. Remarkably, the study reveals that a 2 wt % coal concentration in the ink leads to a substantial improvement in both tensile and flexural properties, resulting in enhancements of 35 and 12.5%, respectively. Additionally, the research demonstrates the printability of various geometries with coal as reinforcement, opening up new possibilities for coal utilization while pursuing more sustainable manufacturing and applications.

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3D-printed in-line and out-of-plane layers with stimuli-responsive intelligence

Cited by 14 publications

References 56 publications

Nozzle Innovations That Improve Capacity and Capabilities of Multimaterial Additive Manufacturing

Nozzle Innovations That Improve Capacity and Capabilities of Multimaterial Additive Manufacturing

3D Printing‐Enabled Design and Manufacturing Strategies for Batteries: A Review

Ink-Based Additive Manufacturing of a Polymer/Coal Composite: A Non-Traditional Reinforcement

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