Abstract Direct ink writing (DIW) using polymer‐particle composite inks is a new research area enabling a wide range of new functionalities. Despite extensive studies, there remains a need for a deeper understanding of how particle size and loading specifically influence printability, especially in the nano range. This work aims to systematically evaluate the effects of SiO2nanoparticle size (26–847 nm) and loading on printability within a polydimethylsiloxane (PDMS) matrix. For the single‐layer printing process, which is influenced by the substrate properties, a 3D printing line analysis (3D‐PLA) is developed to monitor the top and side views of printed lines. It is found that line width varies with ink composition and substrate, while the line height decreases with solvent evaporation, indicating a strong confinement effect from the substrate. For multilayer structures, dual‐layer printing analysis (DLPA) is utilized to evaluate the printability. It is shown that DLPA is independent of the substrate and can be used to compare the printabilities from different inks. Both 3D‐PLA and DLPA can be correlated to the rheological behavior of the ink through ink rheology analysis (IRA). Finally, this research defined the design space for DIW by benchmarking the minimum and maximum particle loadings for printable composite inks. 
                        more » 
                        « less   
                    
                            
                            Machine Learning-Based Modeling of Electric-Field-Assisted Direct Ink Writing (EDIW) Process
                        
                    
    
            Abstract Direct ink writing (DIW) is an extrusion-based additive manufacturing technology. It has gained wide attentions in both industry and research because of its simple design and versatile platform. In electric-field-assisted Direct Ink Writing (eDIW) processes, an external electric field is added between the nozzle and the printing substrate to manipulate the ink-substrate wetting dynamics and therefore optimize the ink printability. eDIW was found effective in printing liquids that are typically difficult to print in the conventional DIW processes. In this paper, an eDIW process modeling system based on machine learning (ML) algorithms is developed. The system is found effective in predicting eDIW printing geometry under varied process parameter settings. Image processing approaches to collect experiment data are developed. Accuracies of different machine learning algorithms for predicting printing results and trace width are compared and discussed. The capabilities, applications and limitations of the presented machine learning-based modeling approach are presented. 
        more » 
        « less   
        
    
    
                            - PAR ID:
- 10469647
- Publisher / Repository:
- American Society of Mechanical Engineers
- Date Published:
- ISBN:
- 978-0-7918-8723-3
- Format(s):
- Medium: X
- Location:
- New Brunswick, New Jersey, USA
- Sponsoring Org:
- National Science Foundation
More Like this
- 
            
- 
            The rapid development of additive manufacturing, also known as three-dimensional (3D) printing, is driving innovations in both industry and academia. Direct ink writing (DIW), an extrusion-based 3D printing technology, can build 3D structures through the deposition of custom-made inks and produce devices with complex architectures, excellent mechanical properties, and enhanced functionalities. A paste-like ink is the key to successful printing. However, as new ink compositions have emerged, the rheological requirements of inks have not been well connected to printability, or the ability of a printed object to maintain its shape and support the weight of subsequent layers. In this review, we provide an overview of the rheological properties of successful DIW inks and propose a classification system based on ink composition. Factors influencing the rheology of different types of ink are discussed, and we propose a framework for describing ink printability using measures of rheology and print resolution. Furthermore, evolving techniques, including computational studies, high-throughput rheological measurements, machine learning, and materiomics, are discussed to illustrate the future directions of feedstock development for DIW. The goals of this review are to assess our current understanding of the relationship between rheological properties and printability, to point out specific challenges and opportunities for development, to provide guidelines to those interested in multi-material DIW, and to pave the way for more efficient, intelligent approaches for DIW ink development.more » « less
- 
            Abstract Direct ink writing (DIW) process is a facile additive manufacturing technology to fabricate three-dimensional (3D) objects with various materials. Its versatility has attracted considerable interest in academia and industry in recent years. As such, upsurging endeavors are invested in advancing the ink flow behaviors in order to optimize the process resolution and the printing quality. However, so far, the physical phenomena during the DIW process are not revealed in detail, leaving a research gap between the physical experiments and its underlying theories. Here, we present a comprehensive analytical study of non-Newtonian ink flow behavior during the DIW process. Different syringe-nozzle geometries are modeled for the comparative case studies. By using the computational fluid dynamics (CFD) simulation method, we reveal the shear-thinning property during the ink extrusion process. Besides, we study the viscosity, shear stress, and velocity fields, and analyze the advantages and drawbacks of each syringe-nozzle model. On the basis of these investigations and analyses, we propose an improved syringe-nozzle geometry for stable extrusion and high printing quality. A set of DIW printing experiments and rheological characterizations are carried out to verify the simulation studies. The results developed in this work offer an in-depth understanding of the ink flow behavior in the DIW process, providing valuable guidelines for optimizing the physical DIW configuration toward high-resolution printing and, consequently, improving the performance of DIW-printed objects.more » « less
- 
            Abstract As a facile and versatile additive manufacturing technology, direct ink writing (DIW) has attracted considerable interest in academia and industry to fabricate three-dimensional structures with unique properties and functionalities. However, so far, the physical phenomena during the DIW process are not revealed in detail, leaving a research gap between the physical experiments and the underlying theories. Here, we presented a comprehensive simulation study of non-Newtonian ink flow during the DIW process. We used the computational fluid dynamics (CFD) method and revealed the shear-thinning behavior during the extrusion process. Different nozzle geometry models were adopted in the simulation. The advantages and drawbacks of each syringe-nozzle geometry were analyzed. In addition, the ink shear stress and velocity fields were investigated and compared in the case studies. Based on these investigations and analysis, we proposed an improved syringe-nozzle geometry towards high-resolution DIW. Consequently, the high-resolution and high shape fidelity DIW could enhance the DIW product performance. The results developed in this work offer valuable guidelines and could accelerate further advancement of DIW.more » « less
- 
            Embedded ink writing (EIW) and direct ink writing (DIW) constitute the primary strategies for three-dimensional (3D) printing within the realm of material extrusion. These methods enable the rapid fabrication of complex 3D structures, utilizing either yield-stress support baths or self-supporting inks. Both these strategies have been extensively studied across a range of fields, including biomedical, soft robotics, and smart sensors, due to their outstanding print fidelity and compatibility with diverse ink materials. Particle additives capable of forming volume-filling 3D networks are frequently incorporated into polymer solvents. This integration is crucial for engineering the requisite microstructures essential for the formulation of successful support bath and ink materials. The interplay between the particle additives and polymer solvents is critical for achieving rheological tunability in various 3D printing strategies, yet this area has not been systematically reviewed. Therefore, in this critical review, we examined various mechanisms of particle–polymer interactions, the resulting microstructures, and their subsequent impact on mechanical and rheological properties. Overall, this work aims to serve as a foundational guideline for the design of next-generation materials in the field of extrusion additive manufacturing, specifically for EIW and DIW.more » « less
 An official website of the United States government
An official website of the United States government 
				
			 
					 
					
 
                                    