Article
Engineering, Electrical & Electronic
M. Ntagios, Ravinder Dahiya
Summary: This work presents a soft, flexible, and low-cost capacitive pressure-sensitive insole developed using resource-efficient single-step 3D printing method. The insole exhibits excellent pressure response and sensitivity, making it a promising solution for applications such as gait analysis and robotics.
IEEE SENSORS JOURNAL
(2023)
Review
Materials Science, Multidisciplinary
Hong Wei Tan, Yu Ying Clarrisa Choong, Che Nan Kuo, Hong Yee Low, Chee Kai Chua
Summary: In recent years, the 3D printed electronics technology has attracted significant attention from industries and researchers due to its unique features. This review provides an in-depth overview of the latest 3D electronic printing techniques, innovative practical technologies, and upcoming application trends in advanced functional materials for fabricating 3D printed electronics devices.
PROGRESS IN MATERIALS SCIENCE
(2022)
Article
Engineering, Manufacturing
Ezgi Kucukdeger, Blake N. Johnson
Summary: This work presents a closed-loop controlled path planning method for microextrusion 3D printing on moving substrates and objects. The method utilizes real-time sensing of local object-tool offset and feedback control of the microextrusion nozzle z-axis position. The method enables conformal microextrusion 3D printing on moving substrates and objects, demonstrating its utility in various emerging applications.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
Review
Nanoscience & Nanotechnology
Guo Liang Goh, Haining Zhang, Tzyy Haur Chong, Wai Yee Yeong
Summary: 3D printing, also known as additive manufacturing, has been utilized in electronics manufacturing for the fabrication of various electronic components and devices. There is ongoing research on 3D printing of multilayered and multimaterial electronics, but a comprehensive review on the design and fabrication consideration is yet to be done.
ADVANCED ELECTRONIC MATERIALS
(2021)
Article
Engineering, Mechanical
Qiang Zhang, Shayuan Weng, Craig M. Hamel, S. Macrae Montgomery, Jiangtao Wu, Xiao Kuang, Kun Zhou, H. Jerry Qi
Summary: This study investigated the volume shrinkage-induced distortion of DLP-printed parts through experiments, theoretical modeling, and FEA simulations, with experiments validating the efficiency of the proposed FEA simulations. FEA was further applied to predict shape distortion in printed microfluidic channels and overhanging structures for designing printing parameters based on FEA.
EXTREME MECHANICS LETTERS
(2021)
Article
Chemistry, Multidisciplinary
Brittany N. Smith, Peter Ballentine, James L. Doherty, Ryan Wence, Hansel Alex Hobbie, Nicholas X. Williams, Aaron D. Franklin
Summary: This study demonstrates the use of aerosol jet printing to create 3D graphene microstructures without any post-print processing, using water as the only solvent. These microstructures exhibit conductivity immediately after printing and can be printed in freestanding configurations. Adding these microstructures to sensor electrodes can enhance sensitivity.
Review
Engineering, Environmental
Jie Zhu, Peiwen Wu, Yanhong Chao, Jiangtao Yu, Wenshuai Zhu, Zhichang Liu, Chunming Xu
Summary: Three-dimensional (3D) printing is revolutionizing the design and manufacturing of 3D objects by transforming digital models into solid models. In the field of catalysis, 3D printing technology offers new possibilities and is widely applied in related catalytic reactions and processes.
CHEMICAL ENGINEERING JOURNAL
(2022)
Review
Chemistry, Multidisciplinary
Manpreet Kaur, Tae-Ho Kim, Woo Soo Kim
Summary: Sensing robots are highly desirable in practical settings, but face challenges such as geometric difficulty in sensor positioning and structural complexity. Integrating 3D electronics into 3D printed objects provides a potential solution for designing realistic sensing robot systems.
ADVANCED MATERIALS
(2021)
Article
Engineering, Manufacturing
Qifeng Qian, Jan Henk Kamps, Brian Price, Hao Gu, Ricky Wildman, Richard Hague, Belen Begines, Christopher Tuck
Summary: In this study, a 3D reactive inkjet printing method was developed to successfully fabricate bisphenol A-polycarbonate material, demonstrating the capability to broaden the range of AM materials to include engineering grade polymers.
ADDITIVE MANUFACTURING
(2022)
Review
Chemistry, Multidisciplinary
Mahsa K. Saghafi, Srivatsan K. Vasantham, Navid Hussain, George Mathew, Federico Colombo, Barbara Schamberger, Eric Pohl, Gabriel Cadilha Marques, Ben Breitung, Motomu Tanaka, Martin Bastmeyer, Christine Selhuber-Unkel, Ute Schepers, Michael Hirtz, Jasmin Aghassi-Hagmann
Summary: The field of bioelectronics aims to connect cells and biological tissues, and has recently been greatly advanced by the development of printable organic, inorganic, and biomaterials, as well as advanced digital printing technologies. Additive manufacturing and 3D printing methods offer new routes for the creation of hybrid bio-/inorganic devices. In this review, the current state and future prospects of printed electronics for interfacing with biological systems are discussed.
ADVANCED FUNCTIONAL MATERIALS
(2023)
Article
Chemistry, Physical
Yuanming Zhang, Tao Zhu, Junke Jiao, Shiyu Song, Zhenqian Wang, Ziwen Wang
Summary: In this study, the optimal forming parameters for printing flexible circuits using aerosol jet printing technology are explored through numerical simulation and experiments. The study found that gas flow rate, working distance, nozzle diameter, and printing speed have a significant impact on the morphology of the printed lines. The printing performance of flexible circuits was validated through single-factor experiments.
Review
Engineering, Multidisciplinary
Xin Ning Zhang, Qiang Zheng, Zi Liang Wu
Summary: This paper reviews the recent progress in 3D printing of tough hydrogels and their applications. It provides an overview of the advantages and requirements of tough hydrogel systems for specific 3D printing technologies, and summarizes the network structures, mechanical performances, toughening mechanisms, and representative applications of the printed tough hydrogels. It also discusses the recent advances in 4D printing of tough hydrogels as a prospective direction for soft actuators and robots.
COMPOSITES PART B-ENGINEERING
(2022)
Article
Chemistry, Physical
Bartlomiej Podsiadly, Andrzej Skalski, Marcin Sloma
Summary: The study investigates the optimal methods for soldering typical electronic components on conductive, 3D-printed, composite substrates, and concludes that mechanical cleaning and using additional flux are necessary to obtain high-quality solder joints.
Article
Engineering, Manufacturing
Habib Nassar, Gaurav Khandelwal, Radu Chirila, Xenofon Karagiorgis, Rebecca E. Ginesi, Abhishek Singh Dahiya, Ravinder Dahiya
Summary: Multi-material additive manufacturing using direct ink writing is a versatile and resource-efficient technique that can produce low-cost sensors and embedded electronic systems. In this study, a fully printed and packaged piezoelectric sensor was successfully fabricated using P(VDF-TrFE)-BaTiO3 as the active material. By adjusting the concentration of BaTiO3 filler, the performance of the sensor can be optimized. The sensor exhibited a linear response in the working range of 0-60 kPa and remained stable under continuous operation for 2200 s. The repeatability of the fabrication process was confirmed, and the sensor was demonstrated to identify objects with different hardness based on dynamic tactile data.
ADDITIVE MANUFACTURING
(2023)
Article
Engineering, Manufacturing
Ticho Ooms, Gieljan Vantyghem, Ruben Van Coile, Wouter De Corte
Summary: This paper proposes a numerical model for simulating the structural behaviour of 3D printed fresh concrete, with the development of a tool that enables automation of the pre-processing step for numerical analysis and simulation of object behaviour during printing.
ADDITIVE MANUFACTURING
(2021)
Review
Materials Science, Composites
B. Yelamanchi, E. MacDonald, N. G. Gonzalez-Canche, J. G. Carrillo, P. Cortes
Summary: This study investigates the mechanical properties of additively-manufacturing-enabled FML, which is a structure composed of metal and composite materials. The results show that the FMLs have good adhesion at the metal-composite interface, but limited intralaminar performance. It was also found that the impact performance of the FMLs improved by 9-13% compared to the constituent elements. The study provides an initial research foundation for using 3D printing in the production of hybrid laminates.
JOURNAL OF THERMOPLASTIC COMPOSITE MATERIALS
(2023)
Article
Metallurgy & Metallurgical Engineering
Brian Vuksanovich, Callan Herberger, Timothy Daugherty, Jason Walker, Pedro Cortes, Eric MacDonald, Dean Jaric, Stephanie Gaffney, Rich Lonardo, Mike Clancy, Richard Huff, Sairam Ravi, Jerry Thiel
Summary: Additive Manufacturing enables casting complex geometries directly from digital design data, but challenges in casting quality and yield arise. Introducing sensors to collect data and improving ventilation design can enhance casting quality.
INTERNATIONAL JOURNAL OF METALCASTING
(2022)
Article
Metallurgy & Metallurgical Engineering
Brian Vuksanovich, Cameron Gygi, Pedro Cortes, Jesus Chavez, Eric MacDonald, Ryan OHara, Anton Du Plessis
Summary: Additive manufacturing is used to digitally fabricate complex sand molds for castings, but inspecting these 3D-printed molds and cores before pouring metal can be challenging. X-ray computed tomography is utilized to evaluate the cleanliness and dimensional accuracy of the cores prior to casting.
INTERNATIONAL JOURNAL OF METALCASTING
(2022)
Article
Polymer Science
Francesco Sillani, Ramis Schiegg, Manfred Schmid, Eric MacDonald, Konrad Wegener
Summary: Powder bed fusion of polymers is increasingly used to customize the properties of end-use products. This study found that the roughness of the top surface of an unmelted powder bed can be used as a proxy for powder bed density.
Article
Computer Science, Information Systems
Khaled Alsharif, Alexander H. Pesch, Vamsi Borra, Frank X. Li, Pedro Cortes, Eric Macdonald, Kyosung Choo
Summary: The study developed an intuitive model for electrochemical cells based on a simple mechanical analogy, which accurately predicted the time-response dynamics of the cells. By optimizing modal parameters and validating the tuned parameters, the mechanical analog model was found to effectively predict the behavior of the cells.
Article
Engineering, Manufacturing
Anton du Plessis, Nima Razavi, Di Wan, Filippo Berto, Adam Imaddadulah, Chad Beamer, James Shipley, Eric MacDonald
Summary: Additive manufacturing of metal components is widely used in high performance applications, particularly in the aerospace industry. Laser powder bed fusion is the most commonly used process, but it has some challenges. Hot isostatic pressing has emerged as a key technology for post-processing metal components and improving fatigue properties.
ADDITIVE MANUFACTURING
(2022)
Review
Engineering, Manufacturing
Thomas Feldhausen, Lauren Heinrich, Kyle Saleeby, Alan Burl, Brian Post, Eric MacDonald, Chris Saldana, Lonnie Love
Summary: Hybrid additive manufacturing combines the advantages of additive and subtractive manufacturing to produce parts with complex geometries, improved surface finish, and precise dimensional accuracy. CAM software plays a crucial role in orchestrating the machine toolpathing for both deposition and machining processes. Different hybrid systems can benefit from optimized toolpath planning to improve the microstructure, mechanical properties, porosity, and residual stress of the final fabricated part.
ADDITIVE MANUFACTURING
(2022)
Article
Engineering, Manufacturing
Kerry Johnson, Edward Burden, Michael Shaffer, Tobias Noack, Matthias Mueller, Jason Walker, Eric MacDonald, Pedro Cortes, Joel Quintana
Summary: Recent advances in additive manufacturing have enabled the rapid fabrication of complex geometries for electromagnetic applications. The introduction of green laser technology has overcome the challenges of printing copper, making it suitable for electrical and electromagnetic applications.
PROGRESS IN ADDITIVE MANUFACTURING
(2022)
Article
Engineering, Mechanical
Agnieszka Chmielewska, Bartlomiej Adam Wysocki, Elzbieta Gadalinska, Eric MacDonald, Boguslawa Adamczyk-Cieslak, David Dean, Wojciech Swieszkowski
Summary: Remelting can improve the density and chemical/phase composition homogeneity of NiTi parts. Increasing the number of remelts reduces the presence of unmixed Ni and Ti elemental powders. The microhardness values of NiTi parts are similar for different numbers of melts. However, multiple phases are present regardless of the number of melt runs according to X-ray diffraction analysis.
RAPID PROTOTYPING JOURNAL
(2022)
Editorial Material
Chemistry, Physical
Alexis Maurel, Ana C. Martinez, Donald A. Dornbusch, William H. Huddleston, Myeong-Lok Seol, Christopher R. Henry, Jennifer M. Jones, Bharat Yelamanchi, Sina Bakhtar Chavari, Jennifer E. Edmunson, Sreeprasad T. Sreenivasan, Pedro Cortes, Eric MacDonald, Cameroun G. Sherrard
ACS ENERGY LETTERS
(2023)
Article
Automation & Control Systems
Thomas Feldhausen, Bharat Yelamanchi, Alexander Gomez, Anton Du Plessis, Lauren Heinrich, Kyle Saleeby, Kenton Fillingim, Brian Post, Lonnie Love, Pedro Cortes, Eric MacDonald
Summary: The combination of additive and subtractive manufacturing in hybrid directed energy deposition allows for the creation of complex geometries with smooth surfaces and high dimensional accuracy. Ceramic inserts are used for various purposes, such as creating composite materials or integrating sensors within a metal structure. Different strategies were tested to successfully embed ceramic components within a 3D-printed stainless steel structure, including the use of wet powder as a thermal barrier and oblique angle laser cladding to redirect thermal energy.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Polymer Science
Charles M. Dwyer, Jose G. Carrillo, Jose Angel Diosdado de la Pena, Carolyn Carradero Santiago, Eric MacDonald, Jerry Rhinehart, Reed M. Williams, Mark Burhop, Bharat Yelamanchi, Pedro Cortes
Summary: Additive manufacturing allows for the production of volumetrically varying lattice structures with tailored mechanical response. The use of elastomers as feedstock provides high viscoelasticity and durability, making them suitable for wearable applications. Siemens' Mithril software was utilized to design different lattice configurations, which were then fabricated using vat photopolymerization and thermoplastic material extrusion processes. Both materials offered unique benefits, with compliance and impact protection provided by SIL30 elastomer and increased stiffness provided by Ultimaker TPU filament.
Proceedings Paper
Computer Science, Information Systems
Grant Parker, Eric MacDonald, Theo Zinner, Mark Yampolskiy
Summary: This paper focuses on the security of indirect manufacturing using additive manufacturing (AM), specifically the creation of molds or mold inserts. The study reveals distinct characteristics and potential security threats of indirect manufacturing compared to direct manufacturing.
CPSS'22: PROCEEDINGS OF THE 8TH ACM CYBER-PHYSICAL SYSTEM SECURITY WORKSHOP
(2022)
Article
Engineering, Electrical & Electronic
Carlos R. Mejias-Morillo, Jayaprakash B. Shivakumar, Seng Loong Yu, Blake Roberts, Pedro Cortes, Eric Macdonald, Anton Polotai, Eduardo A. Rojas-Nastrucci
Summary: Additive manufacturing technology allows for rapid and low-cost prototyping and system repair. This paper investigates the electromagnetic properties of 3D-printed YSZ and platinum ink, and tests the performance of antennas made from these materials, which exhibit high gain and good front-back ratio at specific frequencies.
IEEE OPEN JOURNAL OF ANTENNAS AND PROPAGATION
(2022)
Article
Computer Science, Information Systems
Khaled Alsharif, Alexander H. Pesch, Vamsi Borra, Frank X. Li, Pedro Cortes, Eric Macdonald, Kyosung Choo
Summary: This study extends the dynamic system previously developed for estimating voltage response to accurately estimate the heat generation rate due to electrochemical reactions in lithium-ion batteries. The estimated parameters are coupled with a thermal model to predict temperature profiles, and experimental tests validate the accuracy of the model.