Multi-Material, Multi-Layer Devices Enabled by High Aspect Ratio Micro-Extrusion

在本项目中，将研究通过高纵横比（HAR）微喷嘴对膏体进行微挤压，以制造多材料、多层（M3L）器件。在每一层的组成变化的逐层制造的能力将被研究。为了提供无与伦比的能力来制造当今无法实现的新型M3L器件，将研究从毫米到25微米的各种尺寸的HAR微喷嘴的挤压行为。具有高能量密度的新型三维（3D）超级电容器将作为模型系统来研究M3L技术的挑战。因此，将进行广泛的努力来研究和建立所需糊状物的适当配方，这些糊状物可以使用HAR微喷嘴进行微挤出，并具有假塑性特性，以形成具有所需厚度和均匀成分的大层。制造的3D超级电容器将在结构和电化学方面进行表征，以展示M3L技术在制造耐用、低成本、高性能设备方面的无与伦比的能力。M3L技术将减少零件数量，零件处理，零件运输和零件储存，因为只需要一个加工步骤。此外，M3L技术将提供新的制造能力，生产M3L器件，其成分控制在微米级，可实现所需的功能，尺寸控制跨越5个数量级，可实现高制造率。预计提出的M3L技术可以与传统的制造方法竞争成本效益，更不用说M3L技术可以制造具有新功能的新设备，这是通过当今的制造技术无法实现的。这个项目将对制造技术产生重大影响。它可以大大提高生产率，降低生产成本，增强美国制造业的竞争力。该项目还将为制造和替代能源领域的一名研究生和许多本科生提供良好的教育和培训机会。

In this project, studies of micro-extrusion of pastes through high aspect ratio (HAR) micro-nozzles to fabricate multi-material, multi-layer (M3L) devices will be conducted. The capability for layer-by-layer fabrication with composition variation within each layer will be investigated. To provide unmatched capability for fabricating novel architecture of M3L devices not achievable today, extrusion behavior of various sizes of HAR micro-nozzles starting from millimeters all the way down to 25 micrometers will be studied. Novel three-dimensional (3D) supercapacitors with high energy densities will be used as a model system to investigate the challenges of the M3L technology. As such, extensive efforts will be made to study and establish the proper formulations of the desired pastes that can be micro-extruded using HAR micro-nozzles and have pseudoplastic characteristics to form a large layer with the desired thickness and a uniform composition. The 3D supercapacitors fabricated will be characterized structurally and electro-chemically to demonstrate the unmatched power of the M3L technology in fabricating durable, low cost, high performance devices.M3L technology will reduce part count, part handling, part transportation and part storage because only one processing step is needed. Furthermore, the M3L technology will offer new manufacturing capabilities to produce M3L devices with the composition control locally at the micrometer level for the desired functionalities and the dimension control spanning over 5 orders of magnitude for high fabrication rates. It is expected that the M3L technology proposed can compete with conventional manufacturing methods for cost effectiveness, not to mention that the M3L technology can fabricate novel devices with new functionalities, not achievable via today's manufacturing technology. This project will have a substantial impact on manufacturing technology. It can greatly improve productivity, reduce the production cost, and enhance the U.S. manufacturing competitiveness. This project will also provide an excellent education and training opportunity to one graduate student and many undergraduate students in the areas of manufacturing and alternative energy.