Ryan B. Wicker

Metal Fabrication by Additive Manufacturing Using Laser and Electron Beam Melting Technologies

Selective laser melting (SLM) and electron beam melting (EBM) are relatively new rapid, additive manufacturing technologies which can allow for the fabrication of complex, multi-functional metal or alloy monoliths by CAD-directed, selective melting of precursor powder beds. By altering the beam parameters and scan strategies, new and unusual, even non-equilibrium microstructures can be produced; including controlled microstructural architectures which ideally extend the contemporary materials science and engineering paradigm relating structure-properties-processing-performance. In this study, comparative examples for SLM and EBM fabricated components from pre-alloyed, atomized precursor powders are presented. These include Cu, Ti-6Al-4V, alloy 625 (a Ni-base superalloy), a Co-base superalloy, and 17-4 PH stainless steel. These systems are characterized by optical metallography, scanning and transmission electron microscopy, and X-ray diffraction.

Time-resolved three-dimensional phase-contrast MRI.

To demonstrate the feasibility of a four‐dimensional phase contrast (PC) technique that permits spatial and temporal coverage of an entire three‐dimensional volume, to quantitatively validate its accuracy against an established time resolved two‐dimensional PC technique to explore advantages of the approach with regard to the four‐dimensional nature of the data.

Integrating stereolithography and direct print technologies for 3D structural electronics fabrication

Purpose – The purpose of this paper is to present a hybrid manufacturing system that integrates stereolithography (SL) and direct print (DP) technologies to fabricate three‐dimensional (3D) structures with embedded electronic circuits. A detailed process was developed that enables fabrication of monolithic 3D packages with electronics without removal from the hybrid SL/DP machine during the process. Successful devices are demonstrated consisting of simple 555 timer circuits designed and fabricated in 2D (single layer of routing) and 3D (multiple layers of routing and component placement).Design/methodology/approach – A hybrid SL/DP system was designed and developed using a 3D Systems SL 250/50 machine and an nScrypt micro‐dispensing pump integrated within the SL machine through orthogonally‐aligned linear translation stages. A corresponding manufacturing process was also developed using this system to fabricate 2D and 3D monolithic structures with embedded electronic circuits. The process involved part de...

3D Printing for the Rapid Prototyping of Structural Electronics

In new product development, time to market (TTM) is critical for the success and profitability of next generation products. When these products include sophisticated electronics encased in 3D packaging with complex geometries and intricate detail, TTM can be compromised - resulting in lost opportunity. The use of advanced 3D printing technology enhanced with component placement and electrical interconnect deposition can provide electronic prototypes that now can be rapidly fabricated in comparable time frames as traditional 2D bread-boarded prototypes; however, these 3D prototypes include the advantage of being embedded within more appropriate shapes in order to authentically prototype products earlier in the development cycle. The fabrication freedom offered by 3D printing techniques, such as stereolithography and fused deposition modeling have recently been explored in the context of 3D electronics integration - referred to as 3D structural electronics or 3D printed electronics. Enhanced 3D printing may eventually be employed to manufacture end-use parts and thus offer unit-level customization with local manufacturing; however, until the materials and dimensional accuracies improve (an eventuality), 3D printing technologies can be employed to reduce development times by providing advanced geometrically appropriate electronic prototypes. This paper describes the development process used to design a novelty six-sided gaming die. The die includes a microprocessor and accelerometer, which together detect motion and upon halting, identify the top surface through gravity and illuminate light-emitting diodes for a striking effect. By applying 3D printing of structural electronics to expedite prototyping, the development cycle was reduced from weeks to hours.

Fabrication of Metal and Alloy Components by Additive Manufacturing: Examples of 3D Materials Science

Objective This paper provides a brief review of relatively new additive manufacturing technologies for the fabrication of unusual and complex metal and alloy products by laser and electron beam melting. A number of process features and product microstructures are illustrated utilizing 3D optical and transmission electron microscope image compositions representing examples of 3D materials science. Methods Processing methods involving electron beam melting (EBM) and a process referred to as direct metal laser sintering (DMLS), often called selective laser melting (SLM) are described along with the use of light (optical) microscopy (OM), transmission electron microscopy (TEM), and X-ray diffraction (XRD) to elucidate microstructural phenomena. Results Examples of EBM and SLM studies are presented in 3D image compositions. These include EBM of Ti-6Al-4V, Cu, Co-base superalloy and Inconel 625; and SLM of 17-4 PH stainless steel, Inconel 718 and Inconel 625. Conclusions 3D image compositions constituting 3D materials science provide effective visualization for directional solidification-related phenomena associated with the EBM and SLM fabrication of a range of metals and alloys, especially microstructures and microstructural architectures.

Next generation orthopaedic implants by additive manufacturing using electron beam melting

This paper presents some examples of knee and hip implant components containing porous structures and fabricated in monolithic forms utilizing electron beam melting (EBM). In addition, utilizing stiffness or relative stiffness versus relative density design plots for open-cellular structures (mesh and foam components) of Ti-6Al-4V and Co-29Cr-6Mo alloy fabricated by EBM, it is demonstrated that stiffness-compatible implants can be fabricated for optimal stress shielding for bone regimes as well as bone cell ingrowth. Implications for the fabrication of patient-specific, monolithic, multifunctional orthopaedic implants using EBM are described along with microstructures and mechanical properties characteristic of both Ti-6Al-4V and Co-29Cr-6Mo alloy prototypes, including both solid and open-cellular prototypes manufactured by additive manufacturing (AM) using EBM.

Stereolithography of spatially controlled multi-material bioactive poly(ethylene glycol) scaffolds.

Challenges remain in tissue engineering to control the spatial, mechanical, temporal and biochemical architectures of scaffolds. Unique capabilities of stereolithography (SL) for fabricating multi-material spatially controlled bioactive scaffolds were explored in this work. To accomplish multi-material builds, a mini-vat setup was designed allowing for self-aligning X-Y registration during fabrication. The mini-vat setup allowed the part to be easily removed and rinsed, and different photocrosslinkable solutions to be easily removed and added to the vat. Two photocrosslinkable hydrogel biopolymers, poly(ethylene glycol) dimethacrylate (PEG-dma, MW 1000) and poly(ethylene glycol) diacrylate (PEG-da, MW 3400), were used as the primary scaffold materials. Multi-material scaffolds were fabricated by including controlled concentrations of fluorescently labeled dextran, fluorescently labeled bioactive PEG or bioactive PEG in different regions of the scaffold. The presence of the fluorescent component in specific regions of the scaffold was analyzed with fluorescent microscopy, while human dermal fibroblast cells were seeded on top of the fabricated scaffolds with selective bioactivity and phase contrast microscopy images were used to show specific localization of cells in the regions patterned with bioactive PEG. Multi-material spatial control was successfully demonstrated in features down to 500 microm. In addition, the equilibrium swelling behavior of the two biopolymers after SL fabrication was determined and used to design constructs with the specified dimensions at the swollen state. The use of multi-material SL and the relative ease of conjugating different bioactive ligands or growth factors to PEG allows for the fabrication of tailored three-dimensional constructs with specified spatially controlled bioactivity.

Multiprocess 3D printing for increasing component functionality

BACKGROUND Three-dimensional (3D) printing, known more formally as additive manufacturing, has become the focus of media and public attention in recent years as the decades-old technology has at last approached the performance necessary for direct production of end-use devices. The most popular forms of standard 3D printing include vat photopolymerization, powder bed fusion, material extrusion, sheet lamination, directed energy deposition, material jetting, and binder jetting, each creating parts layer by layer and offering different options in terms of cost, feature detail, and materials. Whereas traditional manufacturing technologies, such as casting, forging, machining, and injection molding, are well suited for mass production of identical commodity items, 3D printing allows for the creation of complex geometric shapes that can be mass-customized, because no die or mold is required and design concepts are translated into products through direct digital manufacturing. Furthermore, the additively layered approach enables the merging of multiple components into a single piece, which removes the requirement for subsequent assembly operations. Recently, the patents for the original 3D printing processes have begun to expire, which is resulting in a burgeoning number of low-cost desktop systems that provide increased accessibility to society at large. Industry has recognized the manufacturing advantages of these technologies and is investing in production systems to make complex components for jet engines, customized bodies for cars, and even pharmaceuticals. Although standard 3D printing technologies have advanced so that it is now possible to print in a wide range of materials including metals, ceramics, and polymers, the resulting structures are generally limited to a single material, or, at best, a limited number of compatible materials. ADVANCES For the technology to become more widely adopted in mainstream manufacturing, 3D printing must provide end-use products by fabricating more than just simple structures with sufficient mechanical strength to retain shape. Recently, research has resulted in the capability to use new materials with commercial 3D printers, and customized printers have been enhanced with complementary traditional manufacturing processes, an approach known as multiprocess or hybrid 3D printing. Collectively, these advancements are leading to fabrications that are not only geometrically complex, but functionally complex as well. By introducing the robotic placement of components, micromachining for intricate detail, embedding of wires, and dispensing of functional inks, complex structures can be constructed with additional electronic, electromagnetic, optical, thermodynamic, chemical, and electromechanical content. OUTLOOK Multiprocess 3D printing is a nascent area of research in which basic 3D printing is augmented to fabricate structures with multifunctionality. Progress will lead to local manufacturing with customized 3D spatial control of material, geometry, and placement of subcomponents. This next generation of printers will allow for the fabrication of arbitrarily shaped end-use devices, leading to direct and distributed manufacturing of products ranging from human organs to satellites. The ramifications are substantial, given that 3D printing will enable the fabrication of customer-specific products locally and on demand, improving personalization and reducing shipping costs and delays. Examples could include replacement components for grain-milling equipment in a remote village in the developing world, biomedical devices created specifically for a patient in a hospital before surgery, and satellite components printed in orbit, thus avoiding the delays and costs associated with launch operations. The automotive, aerospace, defense, pharmaceutical, biomedical, and consumer industries, among others, will benefit from the new design and manufacturing freedom made possible by multiprocess 3D printing. A long-exposure photo of the Multi3D Manufacturing system for multiprocess 3D printing. Two production 3D printers are shown collaboratively printing, with a six-axis robot for conveyance and postprocess assembly. A central gantry in the background incorporatates other complementary manufacturing processes (machining, component placement, wire and foil embedding, and direct write) to provide geometrically complex structures combining polymers, metals, and active components. Layer-by-layer deposition of materials to manufacture parts—better known as three-dimensional (3D) printing or additive manufacturing—has been flourishing as a fabrication process in the past several years and now can create complex geometries for use as models, assembly fixtures, and production molds. Increasing interest has focused on the use of this technology for direct manufacturing of production parts; however, it remains generally limited to single-material fabrication, which can limit the end-use functionality of the fabricated structures. The next generation of 3D printing will entail not only the integration of dissimilar materials but the embedding of active components in order to deliver functionality that was not possible previously. Examples could include arbitrarily shaped electronics with integrated microfluidic thermal management and intelligent prostheses custom-fit to the anatomy of a specific patient. We review the state of the art in multiprocess (or hybrid) 3D printing, in which complementary processes, both novel and traditional, are combined to advance the future of manufacturing.

Cure depth control for complex 3D microstructure fabrication in dynamic mask projection microstereolithography

Purpose – The papers aim is to explore a method using light absorption for improving manufacturing of complex, three‐dimensional (3D) micro‐parts with a previously developed dynamic mask projection microstereolithography (MSL) system. A common issue with stereolithography systems and especially important in MSL is uncontrolled penetration of the ultraviolet light source into the photocrosslinkable resin when fabricating down‐facing surfaces. To accurately fabricate complex 3D parts with down‐facing surfaces, a chemical light absorber, Tinuvin 327™ was mixed in different concentrations into an acrylate‐based photocurable resin, and the solutions were tested for cure depths and successful micro‐part fabrication.Design/methodology/approach – Tinuvin 327 was selected as the light absorber based on its high absorption characteristics (∼0.4) at 365 nm (the filtered light wavelength used in the MSL system). Four concentrations of Tinuvin 327 in resin were used (0.00, 0.05, 0.10, and 0.15 percent (w/w)), and cur...

Advanced metal powder based manufacturing of complex components by electron beam melting

Abstract Electron beam melting of Ti–6Al–4V powder (∼30 μm diameter) to create complex, three-dimensional components layer by layer using CAD is described along with the characterisation of these products (builds) by optical and electron microscopy, and mechanical testing. Build defects, including porous (unmelted or unsintered) zones, inclusions and gas bubbles trapped in the atomised powder particles and retained in the build, are illustrated. Reticulated mesh geometries and their applications are described along with examples having biomedical applications. Microstructures of solid components and mesh arrays are described. Powder chemistries and solid build chemistries are also examined and shown to be constant for up to 40 cycles of powder reuse, but there was a 10–15% reduction in Al content in the solid builds at optimised build conditions. Quality control and related issues are also described using duplicate products for destructive testing correlated with removable quality control tabs on the builds.