skip to main content

Explore Research Products in the NSF-PAR

Title: Nature-inspired materials and structures using 3D Printing
Emulating the unique combination of structural, compositional, and functional gradation in natural materials is exceptionally challenging. Many natural structures have proved too complex or expensive to imitate using traditional processing techniques despite recent advances. Recent innovations within the field of additive manufacturing (AM) or 3D Printing (3DP) have shown the ability to create structures that have variations in material composition, structure, and performance, providing a new design-for-manufacturing platform for the imitation of natural materials. AM or 3DP techniques are capable of manufacturing structures that have significantly improved properties and functionality over what could be traditionally-produced, giving manufacturers an edge in their ability to realize components for highly-specialized applications in different industries. To this end, the present work reviews fundamental advances in the use of naturally-inspired design enabled through 3DP / AM, how these techniques can be further exploited to reach new application areas and the challenges that lie ahead for widespread implementation. An example of how these techniques can be applied towards a total hip arthroplasty application is provided to spur further innovation in this area.  more » « less
Award ID(s):
1934230
NSF-PAR ID:
10282745
Author(s) / Creator(s):
; ;
Date Published:
Journal Name:
Materials science engineering
Volume:
145
ISSN:
0927-796X
Page Range / eLocation ID:
100609
Format(s):
Medium: X
Sponsoring Org:
National Science Foundation
More Like this
  1. ; ; ; ( , Materials science engineering)
    null (Ed.)
    Engineered micro- and macro-structures via additive manufacturing (AM) or 3D-Printing can create structurally varying properties in a part, which is difficult via traditional manufacturing methods. Herein we have utilized powder bed fusion-based selective laser melting (SLM) to fabricate variable lattice structures of Ti6Al4V with uniquely designed unit cell configurations to alter the mechanical performance. Five different configurations were designed based on two natural crystal structures – hexagonal closed packed (HCP) and body centered cubic (BCC). Under compressive loading, as much as 74% difference was observed in compressive strength, and 71% variation in elastic modulus, with all samples having porosities in a similar range of 53 to 65%, indicating the influence of macro-lattice designs alone on mechanical properties. Failure analysis of the fracture surfaces helped with the overall understanding of how configurational effects and unit cell design influences mechanical properties of these samples. Our work highlights the ability to leverage advanced manufacturing techniques to tailor the structural performance of multifunctional components. 
    more » « less
  2. ( , American Society of Engineering Education Annual Conference 2023)
    3D printing (3DP) has been becoming more and more popular throughout the education system from Kindergarten to University. High school is a critical period for students to decide their imminent university major selection which in turn will impact their future career choices. High school students are usually intrigued by hands-on tool such as 3DP which is also an important contributor to other courses such as robotics. The recent years have seen more investment and availability of 3DP in high schools, especially Career and Technical Education (CTE) programs. However, mere availability of 3DP is not enough for teachers to fully utilize its potential in their classrooms. While basic 3DP skills can be obtained through a few hours of training, the basic training is insufficient to ensure effective teaching Engineering Design Process (EDP) at the high school level. To address this problem, this project develops an EDP course tightly integrated with 3DP for preservice teachers (PST) who are going to enter the workforce in high schools. Engineering design process (EDP) has become an essential part for preservice teachers (PST), especially for high school STEM. 3DP brought transformative change to EDP which is an iterative process that needs virtual/physical prototyping. The new PST course on EDP will be purposefully integrated with an in-depth discussion of 3DP. The approach is to dissect a 3D printer’s hardware, explain each component’s function, introduce each component’s manufacturing methods, describe possible defects, and elucidate what works and what does not. This has at least four benefits: 1) PSTs will know what is possibly wrong when a printer or printing process fails, 2) PSTs will learn more manufacturing processes besides 3DP that can be used to support engineering design prototyping, 3) PSTs will know how to design something that can meet the manufacturing constraints, i.e., can be actually fabricated, and 4) reduce errors and frustrations caused by failed design and failed prints which happen frequently to novices in 3DP. After graduation, PSTs will bring the knowledge to their future high schools and will be more confident in teaching engineering design, reverse engineering, prototype development, manufacturing, and technology. The developed course will be implemented and assessed in a future semester. 
    more » « less
  3. ; ( , Materials)
    null (Ed.)
    The physical architecture of materials plays an integral role in determining material properties and functionality. While many processing techniques now exist for fabricating parts of any shape or size, a couple of techniques have emerged as facile and effective methods for creating unique structures: dealloying and additive manufacturing. This review discusses progress and challenges in the integration of dealloying techniques with the additive manufacturing (AM) platform to take advantage of the material processing capabilities established by each field. These methods are uniquely complementary: not only can we use AM to make nanoporous metals of complex, customized shapes—for instance, with applications in biomedical implants and microfluidics—but dealloying can occur simultaneously during AM to produce unique composite materials with nanoscale features of two interpenetrating phases. We discuss the experimental challenges of implementing these processing methods and how future efforts could be directed to address these difficulties. Our premise is that combining these synergistic techniques offers both new avenues for creating 3D functional materials and new functional materials that cannot be synthesized any other way. Dealloying and AM will continue to grow both independently and together as the materials community realizes the potential of this compelling combination. 
    more » « less
  4. ; ( , American Society of Mechanical Engineers)
    Significant progress into the development and use of stretchable sensors for structural health monitoring (SHM) has been made in the last several years. The fusion of stretchable, adaptable sensing materials with highly specialized additive manufacturing techniques allows for the development of highly adaptive, customizable, and easily accessible sensing solutions. However, a significant portion of these works explore SHM topics at a macro level, and with a reduced focus on implementation. As such, little application or experimentation into practical sensing elements, especially those at the micro scale, have followed the advances in sensing technology. In this work, we demonstrate the application of recent developments in stretchable electronics, alongside multiple advanced additive manufacturing processes, to develop a novel flexible microscale sensor. A complex sensor is designed and printed utilizing Digital Light Processing (DLP) to directly fabricate the structure. The printed sensor is then filled with a piezoresistive sensing element of either PEDOT:PSS or carbon-based PDMS (cPDMS), which provided strain readings via resistance change. After being filled with a sensing mixture, the sensor is shown to operate as desired under large deformations. Additionally, the sensor is shown to work effectively when embedded into a separate additively manufactured part. A flexible test coupon is manufactured using the DLP AM process, and a microsensor is embedded inside the coupon structure. This sensing systems is tested in both tension and bending. These results show the feasibility of implementing both modern day AM processes and into current structural health monitoring developments into practical applications. 
    more » « less
  5. ; ( , Additive manufacturing)
    null (Ed.)
    Production-volume and cost requirements currently limit machine tool manufacturers’ ability to produce application-specific tooling with traditional methods, motivating the development of innovative manufacturing technologies. To this end, we detail a manufacturing framework for the design and production of application-specific cutting tools based on industry standard tungsten carbide-cobalt (WC-Co)-based “carbide” cutting materials using additive manufacturing (AM). Herein, novel diamond-reinforced carbide structures were designed and manufactured via AM and subsequently tested in comparison to current commercial products that are traditionally-processed. The resulting diamond-reinforced composites were free from large scale cracking and maintained microstructures with multiple reinforcing phases. Diamond incorporation had a remarkable effect on the processing, microstructure, and machining performance of the WC-Co based material in comparison to a commercial carbide cutting tool of similar composition as well as the base WC-Co matrix. Detailed microstructure and phase analysis, as well as machining experiments, demonstrate the ability to exploit laser-based directed energy deposition (DED)-based AM to create multifunctional cutting tools that can be designed to meet ever-increasing manufacturing demands across many industries. 
    more » « less
  • Citation Formats
  • MLA
  • APA
  • Chicago
  • BibTeX
  • Save / Share this Record
  • Send to Email