skip to main content
US FlagAn official website of the United States government
dot gov icon
Official websites use .gov
A .gov website belongs to an official government organization in the United States.
https lock icon
Secure .gov websites use HTTPS
A lock ( lock ) or https:// means you've safely connected to the .gov website. Share sensitive information only on official, secure websites.


Title: Plasmas for additive manufacturing
Abstract Additive methods for manufacturing materials have recently emerged, particularly for the fabrication of three‐dimensional architectures. Because of their long history in thin‐film etching and deposition, plasmas offer unique advantages for many of the materials and surface processes associated with additive manufacturing. Here, we review recent efforts that have been primarily focused on the direct writing of patterned structures and the post‐treatment of printed materials. Different configurations, materials, and applications are presented. Current challenges and a future outlook are also provided.  more » « less
Award ID(s):
1708742
PAR ID:
10139099
Author(s) / Creator(s):
 ;  ;  
Publisher / Repository:
Wiley Blackwell (John Wiley & Sons)
Date Published:
Journal Name:
Plasma Processes and Polymers
Volume:
17
Issue:
5
ISSN:
1612-8850
Format(s):
Medium: X
Sponsoring Org:
National Science Foundation
More Like this
  1. Mahmoud Amouzadeh Tabrizi (Ed.)
    Agriculturally derived biowastes can be transformed into a diverse range of materials, including powders, fibers, and filaments, which can be used in additive manufacturing methods. This review study reports a study that analyzes the existing literature on the development of novel materials from agriculturally derived biowastes for additive manufacturing methods. A review was conducted of 57 selected publications since 2016 covering various agriculturally derived biowastes, different additive manufacturing methods, and potential large-scale applications of additive manufacturing using these materials. Wood, fish, and algal cultivation wastes were also included in the broader category of agriculturally derived biowastes. Further research and development are required to optimize the use of agriculturally derived biowastes for additive manufacturing, particularly with regard to material innovation, improving print quality and mechanical properties, as well as exploring large-scale industrial applications. 
    more » « less
  2. Abstract Lithium‐ion battery electrodes are manufactured using a new additive manufacturing process based on dry powders. By using dry powder‐based processing, the solvent and its associated drying processes in conventional battery process can be removed, allowing for large‐scale Li‐ion battery production to be more economically viable in markets such as automotive energy storage systems. Uniform mixing distribution of the additive materials throughout the active material is the driving factor for manufacturing dry powder‐based Li‐ion batteries. Therefore, this article focuses on developing a physical model based on interfacial energies to understand the mixing characteristics of the dry mixed particulate materials. The mixing studies show that functional electrodes can be manufactured using dry processing with binder and conductive additive materials as low as 1 wt% due to the uniformly distributed particles. Electrochemical performance of the dry manufactured electrodes with reduced conductive and binder additive is promising as the cells retained 77% capacity after 100 cycles. While not representative of the best possible electrochemical performance of Li‐ion batteries, the achieved electrochemical performance of the reduced conductive and binder additive electrodes with LiCoO2as the active material confirms the well distributed nature of the additive particles throughout the electrode matrix. 
    more » « less
  3. Abstract Thermoset composites, utilized in additive manufacturing, are distinguished by their excellent thermal and mechanical properties, enabling them to maintain structural integrity even under high-temperature conditions. An accurate method for characterizing the mechanical properties is necessary to ensure the performance parameters, reliability, and safety of materials during and post-manufacturing. However, characterizing 3D-printed thermoset composites is challenging due to the anisotropy introduced by the additive manufacturing process and factors such as delamination and porosity. This also leads to difficulties in accurately characterizing composites with traditional testing methods. To address this, this paper introduces a novel method that combines a non-destructive Piezoelectric transducer-laser Doppler Vibrometer (PZT-LDV) guided wave sensing system with an optimization algorithm-enhanced wavenumber analysis technique. A series of experiments were conducted to validate the concept of measuring the mechanical properties of a 3D-printed thermoset material panel. Our method successfully determined two material properties — shear wave speed and Poisson’s ratio in multiple directions on the test panel. This study aims to establish a precise and rapid non-destructive testing method that can effectively characterize various composite materials and monitor their performance throughout the additive manufacturing process. 
    more » « less
  4. Abstract Thermal insulation materials reduce heat transfer and are typically made from materials like fiberglass, foam, or mineral wool, which are engineered to trap air and hinder heat conduction and convection. The traditional manufacturing processes of thermal insulation materials are often energy-intensive and result in significant greenhouse gas emissions. In the current global drive for sustainability, these energy-intensive manufacturing processes raise environmental concerns and need to be addressed. In this work, with the objective of addressing both material sustainability and manufacturing sustainability, we present an additive manufacturing strategy to fabricate biomass materials for thermal insulation applications. We propose utilizing wheat straw as a biomass feedstock for manufacturing sustainable thermal insulation. This approach captures carbon during growth and stores it within the insulation structure. In the presented work, we first demonstrate the formulation of a 3D-printable ink using chopped straw fibers. We conduct comprehensive rheological characterizations to reveal the shear-thinning properties and the printability of the straw fiber ink. Utilizing the direct ink writing (DIW) process, the straw fiber material is deposited into 3D structures. Through material characterization tests, which include microstructure, mechanical, and thermal analyses, we demonstrate the low thermal conductivity and robust mechanical properties. This paper marks the first work of 3D printing of wheat straw fibers for thermal insulation structures. The discoveries in this pilot work demonstrate the potential to leverage additive manufacturing technologies and sustainable biomass materials to create both functional and value-added wheat straw parts tailored for thermal insulation applications. 
    more » « less
  5. Abstract Natural organisms have evolved a series of versatile functional biomaterials and structures to cope with survival crises in their living environment, exhibiting outstanding properties such as superhydrophobicity, anisotropy, and mechanical reinforcement, which have provided abundant inspiration for the design and fabrication of next‐generation multi‐functional devices. However, the lack of available materials and limitations of traditional manufacturing methods for complex multiscale structures have hindered the progress in bio‐inspired manufacturing of functional structures. As a revolutionary emerging manufacturing technology, additive manufacturing (i.e., 3D printing) offers high design flexibility and manufacturing freedom, providing the potential for the fabrication of intricate, multiscale, hierarchical, and multi‐material structures. Herein, a comprehensive review of current 3D printing of surface/interface structures, covering the applied materials, designs, and functional applications is provided. Several bio‐inspired surface structures that have been created using 3D printing technology are highlighted and categorized based on their specific properties and applications, some properties can be applied to multiple applications. The optimized designs of these 3D‐printed bio‐inspired surfaces offer a promising prospect of low‐cost, high efficiency, and excellent performance. Finally, challenges and opportunities in field of fabricating functional surface/interface with more versatile functional material, refined structural design, and better cost‐effective are discussed. 
    more » « less