Jigar Patadiya, Sreenivasan S., Ramdayal Yadav, M. Naebe, B. Kandasubramanian
Strategies for strengthening the characteristics of naturally inspired multilayer composites are being sought, including inorganic platelet alignment, enhancing interlaminar collaboration between polymeric solution and printed platelets, and optimizing soft phase materials. The former tactic is significant because a particle reinforcement can use high in-plane modulus and strength of inorganic mineral bridges and asperities as much as possible. Fly ash is an immense amount of environmental waste from thermal power plants and other industries that can be effectively employed as particle reinforcement in nature-inspired composites. Herein, the study demonstrates an anomalous phenomenon combining soft microscale organic polylactic acid (PLA) components with inorganic micro grains fly ash (FA) hierarchically designed by natural organisms through dual 3D printing technique (fused deposition modeling & direct ink writing). Our investigation of composite deformation reveals that sheet nacreous architecture exhibits the highest flexural and tensile modulus, whereas foliated structure shows better impact resistance. Remarkably, as fly ash filler increases, the mechanical behavior of composites improves as large as 882 MPa and 418 MPa, flexural and elastic modulus, respectively.
{"title":"Harnessing Fly Ash as Particle Reinforcement in Nature-Inspired Multilayer Composites","authors":"Jigar Patadiya, Sreenivasan S., Ramdayal Yadav, M. Naebe, B. Kandasubramanian","doi":"10.1115/1.4065964","DOIUrl":"https://doi.org/10.1115/1.4065964","url":null,"abstract":"\u0000 Strategies for strengthening the characteristics of naturally inspired multilayer composites are being sought, including inorganic platelet alignment, enhancing interlaminar collaboration between polymeric solution and printed platelets, and optimizing soft phase materials. The former tactic is significant because a particle reinforcement can use high in-plane modulus and strength of inorganic mineral bridges and asperities as much as possible. Fly ash is an immense amount of environmental waste from thermal power plants and other industries that can be effectively employed as particle reinforcement in nature-inspired composites. Herein, the study demonstrates an anomalous phenomenon combining soft microscale organic polylactic acid (PLA) components with inorganic micro grains fly ash (FA) hierarchically designed by natural organisms through dual 3D printing technique (fused deposition modeling & direct ink writing). Our investigation of composite deformation reveals that sheet nacreous architecture exhibits the highest flexural and tensile modulus, whereas foliated structure shows better impact resistance. Remarkably, as fly ash filler increases, the mechanical behavior of composites improves as large as 882 MPa and 418 MPa, flexural and elastic modulus, respectively.","PeriodicalId":513355,"journal":{"name":"Journal of Micro- and Nano-Manufacturing","volume":"120 43","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-07-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141820064","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Karson Wardell, Yao Yao, Qingrui Jiang, Shinghua Ding, Yi Wang, Yiwei Han
Three-dimensional (3D) microneedle arrays (MAs) have shown remarkable performances for a wide range of biomedical applications. Achieving advanced customizable 3D MAs for personalized research and treatment remains a formidable challenge. In this paper, we have developed a high-resolution Electrohydrodynamic (EHD) 3D printing process for fabricating customizable 3D MAs with economical and biocompatible molten alloy. The critical printing parameters (i.e., voltage and pressure) on the printing process for both 2D and 3D features are characterized, and an optimal set of printing parameters was obtained for printing 3D MAs. We have also studied the effect of the tip-nozzle separation speed on the final tip dimension, which will directly influence MAs' insertion performance and functions. With the optimal process parameters, we successfully EHD printed customizable 3D MAs with varying spacing distances and shank heights. A 3=3 customized 3D MAs configuration with various heights ranging from 0.8mm to 1mm and a spacing distance as small as 350 um were successfully fabricated, in which the diameter of each individual microneedle was as small as 100 um. A series of tests were conducted to evaluate the printed 3D MAs. The experimental results demonstrated that the printed 3D MAs exhibit good mechanical strength for implanting and good electrical properties for electrophysiological sensing and stimulation. All results showed the potential applications of the EHD printing technique in fabricating cost-effective customizable high-performance MAs for biomedical applications.
三维（3D）微针阵列（MAs）在广泛的生物医学应用中表现出卓越的性能。实现先进的可定制三维微针阵列用于个性化研究和治疗仍然是一项艰巨的挑战。在本文中，我们开发了一种高分辨率电流体动力（EHD）三维打印工艺，利用经济实惠、生物相容性好的熔融合金制造可定制的三维微针。我们确定了二维和三维特征打印过程的关键打印参数（即电压和压力），并获得了打印三维 MA 的最佳打印参数集。我们还研究了针尖-喷嘴分离速度对最终针尖尺寸的影响，这将直接影响 MAs 的插入性能和功能。通过优化工艺参数，我们成功地用 EHD 打印出了可定制的三维 MA，其间距和柄部高度各不相同。我们成功制造出了3=3的定制化三维微针，其高度从0.8毫米到1毫米不等，间距最小为350微米，其中每个微针的直径最小为100微米。为了评估打印出的三维微针，我们进行了一系列测试。实验结果表明，打印出的三维微针具有良好的植入机械强度和电生理传感和刺激电特性。所有结果都表明，电热辐射打印技术在为生物医学应用制造具有成本效益的可定制高性能 MA 方面具有潜在的应用价值。
{"title":"Direct Printing of High-resolution Metallic 3D Microneedle Arrays via Electrohydrodynamic Jet Printing","authors":"Karson Wardell, Yao Yao, Qingrui Jiang, Shinghua Ding, Yi Wang, Yiwei Han","doi":"10.1115/1.4065965","DOIUrl":"https://doi.org/10.1115/1.4065965","url":null,"abstract":"\u0000 Three-dimensional (3D) microneedle arrays (MAs) have shown remarkable performances for a wide range of biomedical applications. Achieving advanced customizable 3D MAs for personalized research and treatment remains a formidable challenge. In this paper, we have developed a high-resolution Electrohydrodynamic (EHD) 3D printing process for fabricating customizable 3D MAs with economical and biocompatible molten alloy. The critical printing parameters (i.e., voltage and pressure) on the printing process for both 2D and 3D features are characterized, and an optimal set of printing parameters was obtained for printing 3D MAs. We have also studied the effect of the tip-nozzle separation speed on the final tip dimension, which will directly influence MAs' insertion performance and functions. With the optimal process parameters, we successfully EHD printed customizable 3D MAs with varying spacing distances and shank heights. A 3=3 customized 3D MAs configuration with various heights ranging from 0.8mm to 1mm and a spacing distance as small as 350 um were successfully fabricated, in which the diameter of each individual microneedle was as small as 100 um. A series of tests were conducted to evaluate the printed 3D MAs. The experimental results demonstrated that the printed 3D MAs exhibit good mechanical strength for implanting and good electrical properties for electrophysiological sensing and stimulation. All results showed the potential applications of the EHD printing technique in fabricating cost-effective customizable high-performance MAs for biomedical applications.","PeriodicalId":513355,"journal":{"name":"Journal of Micro- and Nano-Manufacturing","volume":"24 3","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-07-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141819379","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Recent Advancements in Micro- and Nano-manufacturing From Wcmnm2023 - Part 2","authors":"Ramesh Singh, Pavel Penchev, Tohru Sasaki","doi":"10.1115/1.4065932","DOIUrl":"https://doi.org/10.1115/1.4065932","url":null,"abstract":"","PeriodicalId":513355,"journal":{"name":"Journal of Micro- and Nano-Manufacturing","volume":" 6","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-07-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141833137","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Recent Advancements in Micro- and Nano-Manufacturing From WCMNM2023 - Part 1","authors":"Ramesh Singh, Pavel Penchev, Tohru Sasaki","doi":"10.1115/1.4065931","DOIUrl":"https://doi.org/10.1115/1.4065931","url":null,"abstract":"","PeriodicalId":513355,"journal":{"name":"Journal of Micro- and Nano-Manufacturing","volume":"9 11","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-07-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141645925","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Mahdi Pirani, M. Hahn, Hamed Dardaei Joghan, A. E. Tekkaya, Saeed Farahani
Multi-material design with a combination of solid and foam structures offers a promising avenue for reducing component weight while enhancing their functionalities. However, the complexity of multi-stage manufacturing processes poses significant challenges to adopting such approaches. To address these challenges, this paper introduces an innovative concept known as Electromagnetic Forming Injection Foaming (EFIF), which integrates injection molding, forming, and foaming processes into a single hybrid process. This process begins with a simultaneous filling-forming phase, followed by supercritical fluid (SCF) assisted foaming controlled by electromagnetic forming. Through a series of experimental and analytical studies, this work investigates the feasibility and effectiveness of EFIF. First, the impact of pressure drop rate and pressure drop on cell size and density is examined through a specialized experimental setup enabling performing injection, forming, and foaming processes in a single operation. The potential influence of electromagnetic forming on foam injection molding is explored through experiments focusing on the effects of a polymer layer between sheet metal blank and the electromagnetic coils. Additionally, an analytical study evaluates the EFIF process by calculating expected pressure drop rates under different processing conditions and their influence on cell nucleation rates. The results showed the possibility of achieving pressure drop rates up to 1.5×105 bar/sec, resulting in nucleation rates up to 1.77×109 nuclei/cm3sec. Overall, this paper highlights the potential of EFIF to merge existing technologies into a scalable solution for manufacturing multi-material components with micro- to nanocellular polymer foams.
{"title":"On the Potential of Manufacturing Multi-Material Components with Micro/Nanocellular Structures via the Hybrid Process of Electromagnetic Forming Injection Foaming","authors":"Mahdi Pirani, M. Hahn, Hamed Dardaei Joghan, A. E. Tekkaya, Saeed Farahani","doi":"10.1115/1.4065933","DOIUrl":"https://doi.org/10.1115/1.4065933","url":null,"abstract":"\u0000 Multi-material design with a combination of solid and foam structures offers a promising avenue for reducing component weight while enhancing their functionalities. However, the complexity of multi-stage manufacturing processes poses significant challenges to adopting such approaches. To address these challenges, this paper introduces an innovative concept known as Electromagnetic Forming Injection Foaming (EFIF), which integrates injection molding, forming, and foaming processes into a single hybrid process. This process begins with a simultaneous filling-forming phase, followed by supercritical fluid (SCF) assisted foaming controlled by electromagnetic forming. Through a series of experimental and analytical studies, this work investigates the feasibility and effectiveness of EFIF. First, the impact of pressure drop rate and pressure drop on cell size and density is examined through a specialized experimental setup enabling performing injection, forming, and foaming processes in a single operation. The potential influence of electromagnetic forming on foam injection molding is explored through experiments focusing on the effects of a polymer layer between sheet metal blank and the electromagnetic coils. Additionally, an analytical study evaluates the EFIF process by calculating expected pressure drop rates under different processing conditions and their influence on cell nucleation rates. The results showed the possibility of achieving pressure drop rates up to 1.5×105 bar/sec, resulting in nucleation rates up to 1.77×109 nuclei/cm3sec. Overall, this paper highlights the potential of EFIF to merge existing technologies into a scalable solution for manufacturing multi-material components with micro- to nanocellular polymer foams.","PeriodicalId":513355,"journal":{"name":"Journal of Micro- and Nano-Manufacturing","volume":"16 8","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-07-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141649461","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Electrohydrodynamic (EHD) printing is a versatile process that can be used to pattern high-resolution droplets and fibers through the deposition of an electrified jet. This highly complex process utilizes a coupled hydrodynamic and electrostatic mechanism to drive the fluid flow. While it has many biomedical, electronic, and filtration applications, its widescale usage is hampered by a lack of detailed understanding of the jetting physics that enables this process. In this paper, a numerical model is developed and validated to explore the design space of the EHD jetting process, from Taylor Cone formation to jet impingement onto the substrate, and analyze the key geometrical and process parameters that yield high-resolution structures. This numerical model applies to various process parameters, material properties, and environmental factors and can accurately capture jet evolution, radius, and flight time. It can be used to better inform design decisions when using EHD processes with distinct resolution requirements.
{"title":"Multiphysics Analysis and Verification of Jet Flight in Electrohydrodynamic Printing for Near-Field Electrospinning Applications","authors":"Sanjana Subramaniam, Jian Cao, K. Ehmann","doi":"10.1115/1.4065874","DOIUrl":"https://doi.org/10.1115/1.4065874","url":null,"abstract":"\u0000 Electrohydrodynamic (EHD) printing is a versatile process that can be used to pattern high-resolution droplets and fibers through the deposition of an electrified jet. This highly complex process utilizes a coupled hydrodynamic and electrostatic mechanism to drive the fluid flow. While it has many biomedical, electronic, and filtration applications, its widescale usage is hampered by a lack of detailed understanding of the jetting physics that enables this process. In this paper, a numerical model is developed and validated to explore the design space of the EHD jetting process, from Taylor Cone formation to jet impingement onto the substrate, and analyze the key geometrical and process parameters that yield high-resolution structures. This numerical model applies to various process parameters, material properties, and environmental factors and can accurately capture jet evolution, radius, and flight time. It can be used to better inform design decisions when using EHD processes with distinct resolution requirements.","PeriodicalId":513355,"journal":{"name":"Journal of Micro- and Nano-Manufacturing","volume":"168 4","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141694898","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Two-photon lithography (TPL) is an attractive technique for nanoscale additive manufacturing of functional 3D structures due to its ability to print sub-diffraction features with light. Despite its advantages, it has not been widely adopted due to its slow point-by-point writing mechanism. Projection TPL (P-TPL) is a high-throughput variant that overcomes this limitation by enabling the printing of entire 2D layers at once. However, printing the desired 3D structures is challenging due to the lack of fast and accurate process models. Here, we present a fast and accurate physics-based model of P-TPL to predict the printed geometry and the degree of curing. Our model implements a finite difference method enabled by operator splitting to solve the reaction-diffusion rate equations that govern photopolymerization. When compared with finite element simulations, our model is at least a hundred times faster and its predictions lie within 5% of the predictions of the finite element simulations. This rapid modeling capability enabled performing high-fidelity simulations of printing of arbitrarily complex 3D structures for the first time. We demonstrate how these 3D simulations can predict those aspects of the 3D printing behavior that cannot be captured by simulating the printing of individual 2D layers. Thus, our models provide a resource-efficient and knowledge-based predictive capability that can significantly reduce the need for guesswork-based iterations during process planning and optimization.
{"title":"Rapid Modeling of Photopolymerization in Projection Two-Photon Lithography via an Operator Splitting Finite Difference Method","authors":"Rushil Pingali, S. Saha","doi":"10.1115/1.4065706","DOIUrl":"https://doi.org/10.1115/1.4065706","url":null,"abstract":"\u0000 Two-photon lithography (TPL) is an attractive technique for nanoscale additive manufacturing of functional 3D structures due to its ability to print sub-diffraction features with light. Despite its advantages, it has not been widely adopted due to its slow point-by-point writing mechanism. Projection TPL (P-TPL) is a high-throughput variant that overcomes this limitation by enabling the printing of entire 2D layers at once. However, printing the desired 3D structures is challenging due to the lack of fast and accurate process models. Here, we present a fast and accurate physics-based model of P-TPL to predict the printed geometry and the degree of curing. Our model implements a finite difference method enabled by operator splitting to solve the reaction-diffusion rate equations that govern photopolymerization. When compared with finite element simulations, our model is at least a hundred times faster and its predictions lie within 5% of the predictions of the finite element simulations. This rapid modeling capability enabled performing high-fidelity simulations of printing of arbitrarily complex 3D structures for the first time. We demonstrate how these 3D simulations can predict those aspects of the 3D printing behavior that cannot be captured by simulating the printing of individual 2D layers. Thus, our models provide a resource-efficient and knowledge-based predictive capability that can significantly reduce the need for guesswork-based iterations during process planning and optimization.","PeriodicalId":513355,"journal":{"name":"Journal of Micro- and Nano-Manufacturing","volume":"1 7","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-06-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141363319","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
A micro-cone textured copper sheet was fabricated as an emitter of electromagnetic waves in the near-infrared (IR) to the far-IR wave lengths. This micro-cone texture was aligned in semi-regular by varying the micro-cone size parameters. The micro-cone height (H) was varied from 0.5 µm to 4 µm in average. SEM analysis was utilized to characterize the microstructure of micro-cone textures and to measure the population of micro-cone height (H), its root diameter (B) and pitch (D) with aid of the picture processing and computational geometry. This height population P (H) was compared to the IR emission spectrum, which was measured by the FT-IR (Fourier Transformation IR). Even varying the average height of micro-cone textures, the IR-emission wavelength (λ) abided by the resonance condition by λ ~ 2 x H within the standard deviation of heights and wavelengths. Through the heat radiation experiment in vacuum, the emitted heat flux was estimated to be 58 W/m2 by the one-dimensional heat balance between the heating rate of objective body and the radiated heat flux.
我们制作了一种微锥纹理铜片，作为近红外（IR）至远红外波长电磁波的发射器。通过改变微锥尺寸参数，这种微锥纹理呈半规则排列。微锥高度 (H) 平均从 0.5 微米到 4 微米不等。利用扫描电子显微镜分析微锥纹理的微观结构特征，并借助图片处理和计算几何来测量微锥高度（H）、根直径（B）和间距（D）。该高度群 P (H) 与红外发射光谱进行了比较，后者是通过 FT-IR（傅立叶变换红外光谱）测量的。即使改变微锥纹理的平均高度，在高度和波长的标准偏差范围内，红外发射波长 (λ) 也能遵守共振条件，即 λ ~ 2 x H。通过在真空中进行热辐射实验，利用客观物体的发热率与辐射热流量之间的一维热平衡，估算出辐射热流量为 58 W/m2。
{"title":"Infra-Red Emission for Heat Radiation from Micro-Cone Textured Metallic Sheet Device with Semi-Regular Alignment","authors":"Tatsuhiko Aizawa, Hiroki Nakata, Takeshi Nasu","doi":"10.1115/1.4065684","DOIUrl":"https://doi.org/10.1115/1.4065684","url":null,"abstract":"\u0000 A micro-cone textured copper sheet was fabricated as an emitter of electromagnetic waves in the near-infrared (IR) to the far-IR wave lengths. This micro-cone texture was aligned in semi-regular by varying the micro-cone size parameters. The micro-cone height (H) was varied from 0.5 µm to 4 µm in average. SEM analysis was utilized to characterize the microstructure of micro-cone textures and to measure the population of micro-cone height (H), its root diameter (B) and pitch (D) with aid of the picture processing and computational geometry. This height population P (H) was compared to the IR emission spectrum, which was measured by the FT-IR (Fourier Transformation IR). Even varying the average height of micro-cone textures, the IR-emission wavelength (λ) abided by the resonance condition by λ ~ 2 x H within the standard deviation of heights and wavelengths. Through the heat radiation experiment in vacuum, the emitted heat flux was estimated to be 58 W/m2 by the one-dimensional heat balance between the heating rate of objective body and the radiated heat flux.","PeriodicalId":513355,"journal":{"name":"Journal of Micro- and Nano-Manufacturing","volume":"8 28","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-06-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141265547","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Among the promising techniques within Additive Manufacturing (AM), Direct Ink Writing (DIW) stands out for its ability to work with a wide range of materials, including polymers, ceramics, glass, metals, and cement. However, DIW encounters a significant challenge in creating complex tubular structures, such as vascular scaffolds with micro scale features. To address this challenge, our research investigates a novel method known as Additive Lathe Direct Ink Writing (AL-DIW). AL-DIW entails the precise dispensing of ink onto a rotating mandrel to fabricate intricate hollow tubular structures with overhanging geometries. In this research, we present a series of test cases involving tubular structures, comprising straight-line patterns, curved line designs, and complex stent configurations, to underscore the efficacy of this technique in crafting hollow tubular geometries with micro-scale features. This study not only highlights the capabilities of AL-DIW but also contributes to the broader advancement of additive manufacturing techniques for various applications.
{"title":"Direct Ink Writing on a Rotating Mandrel - Additive Lathe Micro-Manufacturing","authors":"Anupam Ajit Deshpande, Yayue Pan","doi":"10.1115/1.4065506","DOIUrl":"https://doi.org/10.1115/1.4065506","url":null,"abstract":"\u0000 Among the promising techniques within Additive Manufacturing (AM), Direct Ink Writing (DIW) stands out for its ability to work with a wide range of materials, including polymers, ceramics, glass, metals, and cement. However, DIW encounters a significant challenge in creating complex tubular structures, such as vascular scaffolds with micro scale features. To address this challenge, our research investigates a novel method known as Additive Lathe Direct Ink Writing (AL-DIW). AL-DIW entails the precise dispensing of ink onto a rotating mandrel to fabricate intricate hollow tubular structures with overhanging geometries. In this research, we present a series of test cases involving tubular structures, comprising straight-line patterns, curved line designs, and complex stent configurations, to underscore the efficacy of this technique in crafting hollow tubular geometries with micro-scale features. This study not only highlights the capabilities of AL-DIW but also contributes to the broader advancement of additive manufacturing techniques for various applications.","PeriodicalId":513355,"journal":{"name":"Journal of Micro- and Nano-Manufacturing","volume":" 11","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-05-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140997210","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Yulan Zhu, Guodong Liu, Yong Li, H. Tong, Peiyao Cao
Stray current causes undesired material dissolution in micro electrochemical machining (Micro ECM). The reduction of stray corrosion, caused by stray current, continues to be a major challenge for accuracy improvement. To limit the distribution of stray current, a shunt-assisted silicon electrode, with an auxiliary anode sharing stray current, is proposed in this study. The auxiliary anode is arranged outside the insulating layer of the sidewall-insulated electrode. It is proved in simulation that the auxiliary anode can help reduce the average material removal rate on the machined surface by 55% and improve processing accuracy. A fabrication process of shunt-assisted silicon electrode by bulk silicon process and thin film deposition process is presented. Micro grooves and holes are machined in ECM experiments. The angle between each side-wall and the vertical plane is less than 10°. The gap between the sidewall of the machined structures and electrode-outer-contour is about 30 µm ± 6 µm for the grooves and 45 µm ± 10 µm for the holes. These Long term experiments and consistent processing results show the shunt-assisted electrode is reliable in ECM process. But due to the stray corrosion induced by DC power supply and conservative feed method, the effect of the shunt-assisted silicon electrode in inhibiting stray corrosion is not significant. In the future, a micro ECM system with novel power supply and active control methodologies is expected to better utilize the effect of the shunt-assisted silicon electrode.
{"title":"A Shunt-Assisted Silicon Electrode for Micro Electrochemical Machining","authors":"Yulan Zhu, Guodong Liu, Yong Li, H. Tong, Peiyao Cao","doi":"10.1115/1.4065329","DOIUrl":"https://doi.org/10.1115/1.4065329","url":null,"abstract":"\u0000 Stray current causes undesired material dissolution in micro electrochemical machining (Micro ECM). The reduction of stray corrosion, caused by stray current, continues to be a major challenge for accuracy improvement. To limit the distribution of stray current, a shunt-assisted silicon electrode, with an auxiliary anode sharing stray current, is proposed in this study. The auxiliary anode is arranged outside the insulating layer of the sidewall-insulated electrode. It is proved in simulation that the auxiliary anode can help reduce the average material removal rate on the machined surface by 55% and improve processing accuracy. A fabrication process of shunt-assisted silicon electrode by bulk silicon process and thin film deposition process is presented. Micro grooves and holes are machined in ECM experiments. The angle between each side-wall and the vertical plane is less than 10°. The gap between the sidewall of the machined structures and electrode-outer-contour is about 30 µm ± 6 µm for the grooves and 45 µm ± 10 µm for the holes. These Long term experiments and consistent processing results show the shunt-assisted electrode is reliable in ECM process. But due to the stray corrosion induced by DC power supply and conservative feed method, the effect of the shunt-assisted silicon electrode in inhibiting stray corrosion is not significant. In the future, a micro ECM system with novel power supply and active control methodologies is expected to better utilize the effect of the shunt-assisted silicon electrode.","PeriodicalId":513355,"journal":{"name":"Journal of Micro- and Nano-Manufacturing","volume":" 5","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-04-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140689634","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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