An official website of the United States government
Maturing of additive manufacturing (AM) techniques has increased their utilization for fabricating radio frequency (RF) and microwave devices. Solid composites used in material extrusion AM have experienced considerable expansion over the past decade, incorporating functional properties into 3D-printed objects. There are encouraging indications from AM material research that electrically efficient AM materials can be discovered. These materials would be useful for producing microwave components in the future. One of the enabling techniques for fabricating these materials is to incorporate nano/microparticles or fillers into thermoplastic material. Composite material 3D printing is a novel approach to managing materials’ microwave properties. While extrinsic qualities (effective permittivity) can be controlled by shape and porosity management, intrinsic attributes are tied to the composition of composites. Furthermore, combining various materials to increase the spectrum of available microwave characteristics is made possible by multi-material 3D printing. In this chapter, we explore different methodologies to fabricate ceramic/thermoplastic composites for fused deposition modeling (FDM) of RF and microwave devices. Analytical models for predicting effective permittivity of the composite are discussed and application examples of FDM printed RF, microwave and mm-wave devices employing composites are presented.
more »
« less
3D printing of hybrid solid–liquid structures
3D printing is a versatile technology for creating objects with custom geometries and compositions and is increasingly employed for fabricating hybrid solid–liquid composites (SLCs). These composites, comprising solid matrices with integrated liquid components, showcase unique properties such as enhanced flexibility and improved thermal and electrical conductivities. This review focuses on methods to fabricate SLCs directly by different 3D printing techniques, e.g. without needing to backfill or impregnate a porous matrix. The techniques of extrusion, vat photopolymerization and material jetting combined with microfluidics, inkjet printing, vacuum filling and ultraviolet light curing to produce SLCs are emphasized. We also discuss the development of feedstocks, focusing on emulsions and polymer capsules as fillers, and analyze current literature to highlight their significance. The review culminates in a perspective on new directions, highlighting the potential of bicontinuous interfacially jammed emulsion gels (bijels) to facilitate the printing of continuous liquid pathways, alongside the importance of understanding ink formulation and stability. Concluding with future perspectives, we underline the transformative impact of 3D‐printed SLCs in diverse applications, signaling a significant advancement in the field.
more »
« less
- Award ID(s):
- 2103182
- PAR ID:
- 10529170
- Publisher / Repository:
- AIP
- Date Published:
- Journal Name:
- Polymer International
- ISSN:
- 0959-8103
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
More Like this
-
-
Solid-state lithium batteries (SSLBs) are promising candidates for replacing traditional liquid-based Li-ion batteries and revolutionizing battery systems for electric vehicles and portable devices. However, longstanding issues such as form factors, interfacial contact resistance, balance between ion conductivity and mechanical strength, and manufacturing processability limit their applications. In this review we present how advanced printing technologies can help to mitigate typical problems in main components of SSLBs and improve device performance. We first introduce the common printing techniques for energy storage devices, then focus on the issues and corresponding printing strategies for anodes, cathodes, and solid-state electrolytes to guide the construction of energy-dense, free-form SSLBs. The features and effects of the printed structures are emphasized, as well. We conclude by discussing the problems associated with printing technologies and the potential research directions for printed solid-state batteries.more » « less
-
null (Ed.)Purpose This paper aims to summarize the up-to-date research performed on combinations of various biofibers and resin systems used in different three-dimensional (3D) printing technologies, including powder-based, material extrusion, solid-sheet and liquid-based systems. Detailed information about each process, including materials used and process design, are described, with the resultant products’ mechanical properties compared with those of 3D-printed parts produced from pure resin or different material combinations. In most processes introduced in this paper, biofibers are beneficial in improving the mechanical properties of 3D-printed parts and the biodegradability of the parts made using these green materials is also greatly improved. However, research on 3D printing of biofiber-reinforced composites is still far from complete, and there are still many further studies and research areas that could be explored in the future. Design/methodology/approach The paper starts with an overview of the current scenario of the composite manufacturing industry and then the problems of advanced composite materials are pointed out, followed by an introduction of biocomposites. The main body of the paper covers literature reviews of recently emerged 3D printing technologies that were applied to biofiber-reinforced composite materials. This part is classified into subsections based on the form of the starting materials used in the 3D printing process. A comprehensive conclusion is drawn at the end of the paper summarizing the findings by the authors. Findings Most of the biofiber-reinforced 3D-printed products exhibited improved mechanical properties than products printed using pure resin, indicating that biofibers are good replacements for synthetic ones. However, synthetic fibers are far from being completely replaced by biofibers due to several of their disadvantages including higher moisture absorbance, lower thermal stability and mechanical properties. Many studies are being performed to solve these problems, yet there are still some 3D printing technologies in which research concerning biofiber-reinforced composite parts is quite limited. This paper unveils potential research directions that would further develop 3D printing in a sustainable manner. Originality/value This paper is a summary of attempts to use biofibers as reinforcements together with different resin systems as the starting material for 3D printing processes, and most of the currently available 3D printing techniques are included herein. All of these attempts are solutions to some principal problems with current 3D printing processes such as the limit in the variety of materials and the poor mechanical performance of 3D printed parts. Various types of biofibers are involved in these studies. This paper unveils potential research directions that would further widen the use of biofibers in 3D printing in a sustainable manner.more » « less
-
Abstract Most commercial systems for ultraviolet-visible (UV–VIS), Fourier-transform infrared, circular dichroism (CD), and fluorescence spectroscopies are designed for measurement of liquid samples. Moreover, adapters enabling the measurement of solid samples are expensive or unavailable for most commercial instruments. Consequently, there is a significant need for solid sample adapters that enable measurement of both liquid and solid samples with a single system. Here, we report two versions of a solid sample adapter cuvette that can be used in most commercial spectroscopy instruments designed for transmission measurement of liquid samples. One version is designed for techniques that do not require changing the sample orientation, and the other allows easy sample rotation. We successfully fabricated these cuvettes by 3D printing with both fused deposition modeling and stereolithography and demonstrated how they enable us to study the optical properties of macroscopic films of aligned carbon nanotubes by performing UV–VIS and CD spectroscopy measurements with the cuvettes. These 3D printed cuvettes and their implementation will help enable a wide range of experiments at a low cost.more » « less
-
Polymer composites are becoming an important class of materials for a diversified range of industrial applications due to their unique characteristics and natural and synthetic reinforcements. Traditional methods of polymer composite fabrication require machining, manual labor, and increased costs. Therefore, 3D printing technologies have come to the forefront of scientific, industrial, and public attention for customized manufacturing of composite parts having a high degree of control over design, processing parameters, and time. However, poor interfacial adhesion between 3D printed layers can lead to material failure, and therefore, researchers are trying to improve material functionality and extend material lifetime with the addition of reinforcements and self-healing capability. This review provides insights on different materials used for 3D printing of polymer composites to enhance mechanical properties and improve service life of polymer materials. Moreover, 3D printing of flexible energy-storage devices (FESD), including batteries, supercapacitors, and soft robotics using soft materials (polymers), is discussed as well as the application of 3D printing as a platform for bioengineering and earth science applications by using a variety of polymer materials, all of which have great potential for improving future conditions for humanity and planet Earth.more » « less
- Free Publicly Accessible Full Text
-
Accepted Manuscript1.0
- Journal Article:
- https://doi.org/10.1002/pi.6636
