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Register a new userZirconia UV-curable colloids for additive manufacturing via hybrid inkjet printing-stereolithography
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Currently, additive manufacturing of ceramics by stereolithography (SLA) is limited to single materials and by a poor thickness resolution that strongly depends on the ceramic particles-UV light interaction. Combining selective laser curing with inkjet printing represents a novel strategy to overcome these constrains. Nonetheless, this approach requires UV-curable inks that allow hardening of the printed material and sintering to high density. In this work, we report how to design an ink for inkjet printing of yttria stabilized zirconia (YSZ) which can be impressed by addition of UV-curable monomers. We especially show how the formulation of the inks and particularly the UV-monomer concentration impacts the printability and the UV-curing. This leads to prints that are resistant to solvent washing first and densify to 96% dense YSZ layers after sintering.
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Water dispersion of nanometric yttria stabilized zirconia (YSZ) particles synthesized by continuous hydrothermal synthesis are transferred into nanoinks for thin film deposition. YSZ nanoparticles are synthesized in supercritical conditions resulting in highly dispersed crystals of 10 nm in size. The rheology of the colloid is tailored to achieve inkjet printability (Z) by using additives for regulating viscosity and surface tension. Inks with a wide range of properties are produced. A remarkable effect of nanoparticles on the ink printability is registered even at solid load < 1% vol. In particular, nanoparticles hinder the droplet formation at low values of the printability while suitable jetting is observed at high Z values, i.e. Z ca. 20. For the optimized inks, we achieve high quality printing with lateral and thickness resolution of 70 um and ca. 250 nm respectively, as well as self levelling effect with a reduction of the substrate roughness. Densification is achieved at sintering temperatures below 1200 C.
Recent advances in the understanding and control of quantum technologies, such as those based on cold atoms, have resulted in devices with extraordinary metrological sensitivities. To realise this potential outside of a lab environment the size, weight and power consumption need to be reduced. Here we demonstrate the use of laser powder bed fusion, an additive manufacturing technique, as a production technique for the components that make up quantum sensors. As a demonstration we have constructed two key components using additive manufacturing, namely magnetic shielding and vacuum chambers. The initial prototypes for magnetic shields show shielding factors within a factor of 3 of conventional approaches. The vacuum demonstrator device shows that 3D-printed titanium structures are suitable for use as vacuum chambers, with the test system reaching base pressures of $5 pm 0.5 times 10^{-10}$ mbar. These demonstrations show considerable promise for the use of additive manufacturing for cold atom based quantum technologies, in future enabling improved integrated structures, allowing for the reduction in size, weight and assembly complexity.
Additive manufacturing (AM) techniques have gained interest in the tissue engineering field thanks to their versatility and unique possibilities of producing constructs with complex macroscopic geometries and defined patterns. Recently, composite materials - namely heterogeneous biomaterials identified as continuous phase (matrix) and reinforcement (filler) - have been proposed as inks that can be processed by AM to obtain scaffolds with improved biomimetic and bioactive properties. Significant efforts have been dedicated to hydroxyapatite (HA)-reinforced composites, especially targeting bone tissue engineering, thanks to the chemical similarities of HA with respect to mineral components of native mineralized tissues. Here we review applications of AM techniques to process HA-reinforced composites and biocomposites for the production of scaffolds with biological matrices, including cellular tissues. The primary outcomes of recent investigations in terms of morphological, structural, and in vitro and in vivo biological properties of the materials are discussed. We classify the approaches based on the nature of the matrices employed to embed the HA reinforcements and produce the tissue substitutes and report a critical discussion on the presented state of the art as well as the future perspectives, to offer a comprehensive picture of the strategies investigated as well as challenges in this emerging field.
During the laser powder bed fusion (L-PBF) process, the built part undergoes multiple rapid heating-cooling cycles, leading to complex microstructures with nonuniform properties. In the present work, a computational framework, which weakly couples a finite element thermal model to a non-equilibrium PF model was developed to investigate the rapid solidification microstructure of a Ni-Nb alloy during L-PBF. The framework is utilized to predict the spatial variation of the morphology and size of cellular segregation structure as well as the microsegregation in single-track melt pool microstructures obtained under different process conditions. A solidification map demonstrating the variation of microstructural features as a function of the temperature gradient and growth rate is presented. A planar to cellular transition is predicted in the majority of keyhole mode melt pools, while a planar interface is predominant in conduction mode melt pools. The predicted morphology and size of the cellular segregation structure agrees well with experimental measurements.
The surface properties of a substrate are among the most important parameters in the printing technology of functional materials, determining not only the printing resolution but also the stability of the printed features. This paper addresses the wetting difficulties encountered during inkjet printing on homogeneous substrates as a result of improper surface properties. We show that the wetting of a substrate and, consequently, the quality of the printed pattern, can be mediated through the deposition of polymeric layers that are a few nanometers thick. The chemical nature of the polymers determines the surface energy and polarity of the thin layer. Some applications, however, require a rigorous adjustment of the surface properties. We propose a simple and precise method of surface-energy tailoring based on the thermal decomposition of poly(methyl methacrylate) (PMMA) layers. A smooth transition in the wetting occurs when the thickness of the PMMA layer approaches zero, probably due to percolating the underlying surface of the substrate, which enables the inkjet printing of complex structures with a high resolution. In particular, the wetting of three substrate-ink systems was successfully adjusted using the thin polymeric layer: (i) a tantalum-oxide-based ink on indium-tin-oxide-coated glass, (ii) a ferroelectric lead zirconate titanate ink on a platinized silicon substrate, and (iii) a silver nanoparticle ink on an alumina substrate.
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