Abstract In order to improve the quality of products during additive manufacturing, we developed a novel freezing sublimation-based method for inkjet-based three-dimensional (3D) printing technology, which can significantly improve the uniformity of material distribution in printed products. In our previous studies, we used a laboratory prototype with single droplets of inkjet solution containing colloidal particles to prove the concept of this study. However, understanding the interaction between droplets on the printing substrate surface is also crucial for determining the printing resolution and accuracy of this method, which cannot be fully investigated through single droplet-based experimental studies. To fill this knowledge gap, we conducted a series of experiments on colloidal droplet impingement, freezing, and sublimation on substrates using dual droplets. The experimental setup allowed the release of two droplets in quick succession from a modified nozzle with two needles. These droplets coalesced on the substrate surface due to spreading during their impingement processes. Observations revealed that the coalescence pattern of these two droplets varied depending on the time interval between their release. When the second droplet was released immediately after the first, their coalescence was governed by fluid dynamics. However, when the second droplet was released after the first droplet had frozen on the substrate, it spread above the ice surface of the first droplet in a relatively slower process. This observation provides new insights for the continued study and optimization of the proposed novel freezing sublimation-based 3D printing method. 
                        more » 
                        « less   
                    
                            
                            Study of Layer Formation During Droplet-Based 3D Printing of Gel Structures
                        
                    
    
            Additive manufacturing, also known as three-dimensional (3D) printing, is an approach in which a structure may be fabricated layer by layer. For 3D inkjet printing, droplets are ejected from a nozzle and each layer is formed droplet by droplet. Inkjet printing has been widely applied for the fabrication of 3D biological gel structures, but the knowledge of the microscale interactions between printed droplets is still largely elusive. This study aims to elucidate the alginate layer formation process during drop-on-demand inkjet printing using high speed imaging and particle image velocimetry. Droplets are found to impact, spread, and coalesce within a fluid region at the deposition site, forming coherent printed lines within a layer. Interfaces are found to form between printed lines within a layer depending on printing conditions and printing path orientation. The effects of printing conditions on the behavior of droplets during layer formation are discussed and modeled based on gelation dynamics, and recommendations are presented to enable controllable and reliable fabrication of gel structures. 
        more » 
        « less   
        
    
                            - Award ID(s):
- 1634755
- PAR ID:
- 10056159
- Date Published:
- Journal Name:
- ASME 2017 12th International Manufacturing Science and Engineering Conference collocated with the JSME/ASME 2017 6th International Conference on Materials and Processing
- Volume:
- 4
- Page Range / eLocation ID:
- V004T05A019
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
More Like this
- 
            
- 
            Inkjet-based three-dimensional (3D) printing is widely used for fast and efficient non-contact manufacturing, yet it suffers from several drawbacks, such as coarse resolution, lack of adhesion, manufacturing inconsistency, and uncertain final part mechanical properties. These undesirable effects are related to complex flow phenomena in colloidal droplets in inkjet 3D printing, particularly the internal flows and droplet deformations during the deposition and drying processes. These challenges are due to the colloidal suspension droplets being kept in the liquid state during printing. To overcome these disadvantages, this paper presents a novel freezing-sublimation-based inkjet 3D printing concept that freezes the colloidal droplets upon impact followed by sublimation, eliminating the undesirable particle transport and fluid motions during deposition. A series of experiments were conducted to characterize the colloidal droplet behaviors during the impinging/freezing and sublimation processes and evaluate the effects of the freezing process on droplet impinging dynamics as well as the final deposition patterns through sublimation. It was demonstrated that the deposition patterns obtained from this new method are much more uniform than the conventional evaporation-based deposition method. Both qualitative and quantitative methods were applied to analyze the colloidal droplet profiles during the printing process (impinging, freezing, and sublimation), as well as the final deposition patterns. The study shows promising results of using this new method, providing a foundation for the development of the novel freezing-sublimation-based inkjet 3D printing technique.more » « less
- 
            Binder Jet (BJ) additive manufacturing creates parts by binding powder particles together with inkjet-printed droplets. BJ shows promise as an industrial process, but poor final part properties often limit applications. Prior work has shown that there is significant powder rearrangement from the kinetic impact of binder droplets that may contribute to the formation of defects in the final parts. This study builds upon previous research by studying the effects of print parameters, including droplet spacing and inter-arrival time, and droplet parameters, including droplet volume, velocity, and satellite formation, on the formation of lines. A new method, using an adhesive film, for extracting single-layer parts is described which allows for study of smaller, more sensitive primitives. The results show that pre-wetting the powder bed expands the feasible design space and allows printing with larger droplet spacings, smaller inter-arrival times, and slower droplet velocities. This enables up to 50 % faster print rates and the potential for reduced powder relocation due to droplet impact. Results from this work can be used to inform the selection of optimal process parameters and the design of new BJ systems to produce higher quality parts.more » « less
- 
            null (Ed.)Binder Jetting (BJ) is a low-cost Additive Manufacturing (AM) process that uses inkjet technology to selectively bind particles in a powder bed. BJ relies on the ability to control, not only the placement of binder on the surface but also its imbibition into the powder bed. This is a complex process in which picoliter-sized droplets impact powder beds at velocities of 1–10 m/s. However, the effects of printing parameters such as droplet velocity, size, spacing, and inter-arrival time on saturation level (fraction of pore space filled with binder) and line formation (merging of droplets to form a line) are unknown. Prior attempts to predict saturation levels with simple measurements of droplet primitives and capillary pressure assume that droplet/powder interactions are dominated by static equilibrium and neglect the impact of printing parameters. This study analyzes the influence of these parameters on the effective saturation level and conditions for line formation when printing single lines into powder beds of varied materials (316 stainless steel, 420 stainless steel, and alumina) and varied particle size (d50=10–47 µm). Results show that increasing droplet velocity or droplet spacing decreases effective saturation while droplet spacing, velocity, and inter-arrival time affect line formation. At constant printing velocity, the conditions for successful line printing are shown to be a function of droplet spacing and square root of the droplet inter-arrival time analogous to the Washburn model for infiltration into a porous media. The results have implications to maximizing build rates and improving quality of small features in BJ.more » « less
- 
            Abstract Inkjet printing (IJP) is an additive manufacturing process capable to produce intricate functional structures. The IJP process performance and the quality of the printed parts are considerably affected by the deposited droplets’ volume. Obtaining consistent droplets volume during the process is difficult to achieve because the droplets are prone to variations due to various material properties, process parameters, and environmental conditions. Experimental (i.e., IJP setup observations) and computational (i.e., computational fluid dynamics (CFD)) analysis are used to study the droplets variability; however, they are expensive and computationally inefficient, respectively. The objective of this paper is to propose a framework that can perform fast and accurate droplet volume predictions for unseen IJP driving voltage regimes. A two-step approach is adopted: (1) an emulator is constructed from the physics-based droplet volume simulations to overcome the computational complexity and (2) the emulator is calibrated by incorporating the experimental IJP observations. In particular, a scaled Gaussian stochastic process (s-GaSP) is deployed for the emulation and calibration. The resulting surrogate model is able to rapidly and accurately predict the IJP droplets volume. The proposed methodology is demonstrated by calibrating the simulated data (i.e., CFD droplet simulations) emulator with experimental data from two distinct materials, namely glycerol and isopropyl alcohol.more » « less
 An official website of the United States government
An official website of the United States government 
				
			 
					 
					
 
                                    