Combinatorial Additive Manufacturing Approach for Fabricating Nano/Micro 3D Structures

用于制造纳米/微米 3D 结构的组合增材制造方法

• 批准号: 1435649
• 负责人: Salil Desai
• 金额: $ 24.96万
• 依托单位: North Carolina Agricultural & Technical State University
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2014
• 资助国家: 美国
• 起止时间: 2014-08-01 至 2019-07-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1435649&HistoricalAwards=false
• 关键词: Combinatorial; Additive; Manufacturing; Approach; Fabricating

The fabrication of three dimensional structures in free space is important for building certain miniaturized devices. Additive manufacturing popularly called as 3D printing is critical in advancing this field. Over the past three decades additive manufacturing methods have been explored to build complex parts using metals, ceramics and polymers. However, many of these methods can fabricate structures at a fixed dimension with minimal control on the local composition and microstructure. This limits their applicability to the manufacturing of novel devices which require variation in local topography. This research aims to develop a combinatorial additive process by combining microextrusion and droplet based fabrication methods. The hybrid manufacturing method will enable the fabrication of structures that have controlled density, material content, lattice structure, porosity and geometrical configuration based on the application intent. Typical applications include tissue engineering scaffolds, high performance energy devices, and embedded electronics for aerospace components. This research will positively impact the US economy by spurring jobs within the industrial sector and lead to fundamental process investigations within the academic and research communities. This research will impact underrepresented students in discovery based learning of advanced manufacturing methods at a historically black university. This research investigates the additive manufacturing of hierarchical nano/microstructures using a combination of filament based micro extrusion and droplet based manufacturing. The objectives of this research include: (1) understanding micro/nano structure formations using the hybrid approach; (2) studying the filament extrusion, nano/micro droplet deposition, laser irradiation and solidification of materials; and (3) establishing relationships among interacting process parameters by experimental design of hybrid process. The micro extrusion process will be employed to deposit microscale filaments of material based on the nozzle size. These filament lattice structures will be deposited with droplets ranging from nano to micro size based on a scalable direct-write manufacturing method. The droplet content can range from molten metal, polymers to nanoparticle solutions which serve as an effective method to infiltrate selective regions of the filament to produce the desired microstructure and material property. High power CO2 laser system will be used to selectively sinter the deposited structures in multiple layers to generate a 3D part. Using finite element analysis and molecular dynamics models, computational models will be developed to study intriguing multiphysics phenomena during the interaction of micro filament structures with micro and nano droplets.

在自由空间中制造三维结构对于构建某些小型化器件是重要的。增材制造通常被称为3D打印，对于推进这一领域至关重要。在过去的三十年里，人们一直在探索增材制造方法，以使用金属、陶瓷和聚合物来制造复杂的零件。然而，这些方法中的许多方法可以以固定的尺寸制造结构，而对局部组成和微观结构的控制最小。这限制了它们在制造需要局部形貌变化的新型器件方面的适用性。本研究的目的是开发一种组合添加剂工艺相结合的微挤压和液滴为基础的制造方法。混合制造方法将使得能够基于应用意图制造具有受控密度、材料含量、晶格结构、孔隙率和几何构型的结构。典型的应用包括组织工程支架、高性能能源设备和用于航空航天部件的嵌入式电子设备。这项研究将通过刺激工业部门的就业机会对美国经济产生积极影响，并导致学术和研究界的基本过程调查。这项研究将影响在历史上黑人大学的先进制造方法的发现为基础的学习代表性不足的学生。本研究调查分层纳米/微米结构的增材制造使用基于细丝的微挤出和基于液滴的制造的组合。本研究的目的包括：（1）理解微/纳米结构形成的混合方法;（2）研究细丝挤出，纳米/微米液滴沉积，激光照射和固化材料;（3）建立相互作用的工艺参数之间的关系，通过实验设计的混合过程。微挤出工艺将用于基于喷嘴尺寸沉积材料的存款微尺度细丝。这些细丝晶格结构将基于可扩展的直写制造方法沉积从纳米到微米尺寸的液滴。液滴含量的范围可以从熔融金属、聚合物到纳米颗粒溶液，其用作渗透长丝的选择性区域以产生期望的微结构和材料性质的有效方法。高功率CO2激光系统将用于选择性地烧结多层沉积结构以生成3D部件。使用有限元分析和分子动力学模型，计算模型将被开发来研究有趣的多物理现象，在微细丝结构与微米和纳米液滴的相互作用。