5-axis multi-material 3D printing of curved electrical traces

Hong, Freddie; Lampret, Borut; Myant, Connor; Hodges, Steve; Boyle, David E.

doi:10.1016/j.addma.2023.103546

Cited by 8 publications

(3 citation statements)

References 22 publications

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“…In this respect additive manufacturing can open up pathways to 3D DC metamaterials [58], e.g. through 5axis printing [59]. Evenmore, the findings also hold merit for other material extrusion-based printing methods similar to FFF, such as Direct Ink Writing (DIW), as well as other layered materials, such as CFRP.…”

Section: Discussionmentioning

confidence: 84%

DC Electric Metamaterial Behavior in Fused Filament Fabrication Prints With Tuned Interfaces

Dijkshoorn,

Hamstra,

Sanders

et al. 2024

IEEE Flex. Electron.

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DC Electric metamaterials are interesting for electronics, sensors and actuators by enabling steering of current. In this paper we realize such DC electric metamaterials with Fused Filament Fabrication by tuning the nozzle temperature, bed temperature and extrusion width to achieve anisotropic electrical conduction. Both temperatures influence the magnitude of the contact resistance between printed lines, whereas the extrusion width determines the number of interfaces per unit length. An anisotropic effective medium approximation model is used to analyze the effect of the electrical parameters and is verified with Finite Element (FEM) simulations. Measurements are performed with a setup inspired by the pseudo-Hall effect. Finally, exploiting the anisotropic properties of 3D printed conductors, we present a current concentrator and its operation is demonstrated through IR thermography and voltage measurements.

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Section: Discussionmentioning

confidence: 84%

DC Electric Metamaterial Behavior in Fused Filament Fabrication Prints With Tuned Interfaces

Dijkshoorn,

Hamstra,

Sanders

et al. 2024

IEEE Flex. Electron.

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“…Based on the outstanding designability, simplicity, and fast forming process of the 5-axis 3D-printing, conformal conductive patterns and multilayer TFSGs were successfully fabricated on curved surfaces (Figure h,i and Movie S1). Compared to traditional 3-axis printing, the utilization of 4/5-axis technology in this study can significantly improve the quality of the conformal features and also eliminate oozing and stringing. − Moreover, when contrasted with projection microstereolithography-based printing, it supports a higher printable viscosity and a broader material applicability . Therefore, this work paves the way toward the development of a novel class of high stability and low TCR in situ TFSGs for use in metallic components such as turbine blades.…”

Section: Resultsmentioning

confidence: 97%

All-Three-Dimensionally-Printed AgPd Thick-Film Strain Gauge with a Glass–Ceramic Protective Layer for High-Temperature Applications

Zeng,

Chen,

Zhao

et al. 2023

ACS Appl. Mater. Interfaces

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A high-temperature thin/thick-film strain gauge (TFSG) shows development prospects for in situ strain monitoring of hot-end components due to their small perturbations, no damage, and fast response. Direct ink writing (DIW) 3D printing is an emerging and facile approach for the rapid fabrication of TFSG. However, TFSGs prepared based on 3D printing with both high thermal stability and low temperature coefficient of resistance (TCR) over a wide temperature range remain a great challenge. Here, we report a AgPd TFSG with a glass–ceramic protective layer based on DIW. By encapsulating the AgPd sensitive layer and regulating the Pd content, the AgPd TFSG demonstrated a low TCR (191.6 ppm/°C) from 50 to 800 °C and ultrahigh stability (with a resistance drift rate of 0.14%/h at 800 °C). Meanwhile, the achieved specifications for strain detection included a strain sensing range of ±500 με, fast response time of 153 ms, gauge factor of 0.75 at 800 °C, and high durability of >8000 cyclic loading tests. The AgPd TFSG effectively monitors strain in superalloys and can be directly deposited onto cylindrical surfaces, demonstrating the scalability of the presented approach. This work provides a strategy to develop TFSGs for in situ sensing of complex curved surfaces in harsh environments.

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“…This approach provides a reasonable solution, offering a user-friendly interface that may be more accessible to mechanical engineers who may not have extensive programming skills. The integration of Grasshopper into Rhinoceros 3D facilitates the development of customized and intricate toolpaths for multi-axis 3D printing with robotics, potentially overcoming some of the barriers associated with this advanced manufacturing technique [5,6].…”

Section: Introductionmentioning

confidence: 99%

Determination of Design Limitations of Curved Profiles Manufactured by Robotics Non-Planar Additive Manufacturing

Štefčák,

Gajdoš,

Slota

et al. 2024

Adv. Sci. Technol. Res. J.

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The emerging trend of employing 4 or more axes multi-purpose and gantry industrial robots in large format additive manufacturing presents numerous opportunities as well as challenges. The capacity to handle substantial material quantities and rapidly produce prototypes, instrumentation, and final products of considerable dimensions necessitates the formulation of a well-suited production strategy. This involves setting production parameters to minimize material consumption and production time, considering the limitations of the utilized technologies, and ensuring the final product's quality. While slicers are commonly employed for establishing manufacturing strategies and production parameters, most additive manufacturing slicers are optimized for planar 3 axes 3D printing. This limitation hinders their ability to generate non-planar and freeform toolpaths. To overcome this constraint, this paper delves into the utilization of parametric modelling as a potent tool in the realm of non-planar additive manufacturing. It explores the possibilities offered by Rhinoceros Grasshopper software in designing toolpath strategies and fabricating non-planar layers. The paper addresses the associated challenges and limitations of parametric modelling, including computational complexity and the requirement for specialized software and expertise. It emphasizes the crucial need to strike a balance between design complexity and manufacturability to ensure the successful implementation of non-planar additive manufacturing processes.

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5-axis multi-material 3D printing of curved electrical traces

Cited by 8 publications

References 22 publications

DC Electric Metamaterial Behavior in Fused Filament Fabrication Prints With Tuned Interfaces

DC Electric Metamaterial Behavior in Fused Filament Fabrication Prints With Tuned Interfaces

All-Three-Dimensionally-Printed AgPd Thick-Film Strain Gauge with a Glass–Ceramic Protective Layer for High-Temperature Applications

Determination of Design Limitations of Curved Profiles Manufactured by Robotics Non-Planar Additive Manufacturing

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