Nanoscale Solid Freeform Fabrication Process with a Photo-Assisted Spark Plasma Thermal Source

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The research objective of this project is to develop a novel photo-thermal nanomanufacturing process for the creation of nanoscale three-dimensional structures by depositing materials in a direct-write, layer-by-layer fashion. The process uses laser-assisted spark plasmas formed between a nanoprobe tip and a material surface to densify nanoparticles. By adjusting the electrical and laser energies, the thermal energy will be controlled to sinter, consolidate and bond nanoparticle layers to the surface. The outcomes of this research effort will be: 1) demonstration of the capabilities of this unique nano-localized laser-assisted spark plasma heat source for freeform fabrication of nanoscale 3-D metal features by nanoparticle sintering; and 2) characterization of the heat and mass transfer at the electrodes and affects on nanoparticles and nearby surfaces.If successful, the results will shed new light on spark plasmas and thermal materials processes and fabrication at the nanoscale. The potential opportunities for nanoscale 3-D solid freeform fabrication that will be offered by the process are largely unexplored and the process represents a new paradigm for non-clean room nanomanufacturing processes. The development of this process and the understanding of nanoscale transport phenomena associated with it will foster the creation of practical 3-D nanoscale materials deposition equipment, promising even more far-reaching future developments. The research will be integrated into existing and new courses in the investigators program and other steps will be taken to stimulate the interest of undergraduates and minority student engineers in nanotechnology.