Structural Electronics through Additive Manufacturing and Micro-Dispensing

2010 ◽  
Vol 2010 (1) ◽  
pp. 000940-000946 ◽  
Author(s):  
Richard Olivas ◽  
Rudy Salas ◽  
Dan Muse ◽  
Eric MacDonald ◽  
Ryan Wicker ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Printed Circuit Boards ◽  
Fused Deposition Modeling ◽  
Complex Form ◽  
Circuit Boards ◽  
Ultrasonic Consolidation ◽  
Integrated Electronics ◽  
Fused Deposition ◽  
Novel Approach ◽  
Structural Electronics

Implementing electronics systems that are conformal with curved and complex surfaces is difficult if not impossible with traditional fabrication techniques, which require stiff, two dimensional printed circuit boards (PCB). Flexible copper based fabrication is currently available commercially providing conformance, but not simultaneously stiffness. Consequently, these systems are susceptible to reliability problems if bent or stretched repeatedly. The integration of Additive Manufacturing (AM) combined with Direct Print (DP) micro-dispensing can provide shapes of arbitrary and complex form which incorporate 1) miniature cavities for insetting electronic components and 2) conductive traces for electrical interconnect between components. The fabrication freedom introduced by AM techniques such as stereolithography (SL), ultrasonic consolidation (UC), and fused deposition modeling (FDM) have only recently been explored in the context of electronics integration. Advanced dispensing processes have been integrated into these systems allowing for the introduction of conductive inks to serve as electrical interconnect within intricately-detailed dielectric structures. This paper describes a process that provides a novel approach for the fabrication of stiff conformal structures with integrated electronics and describes several prototype demonstrations: a body conformal helmet insert for detection of Traumatic Brain Injury (TBI), a 3D magnetic flux sensor with LED indicators for magnitude and direction and a floating sensor capable of detecting impurities in water while maintaining orientation through density gradients.

scholarly journals EFFECT OF EXTRUSION PROCESS PARAMETERS ON MECHANICAL PROPERTIES OF 3D PRINTED PLA PRODUCT

2021 ◽  
Vol 6 (2) ◽  
pp. 119
Author(s):  
Nanang Ali Sutisna ◽  
Rakha Amrillah Fattah
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Extrusion Process ◽  
Experimental Procedure ◽  
Fused Deposition ◽  
Novel Approach ◽  
Deposition Modeling ◽  
3D Printed ◽  
3D Digital Models

The method of producing items through synchronously depositing material level by level, based on 3D digital models, is named Additive Manufacturing (AM) or 3D-printing. Amongs many AM methods, the Fused Deposition Modeling (FDM) technique along with PLA (Polylactic acid) material is commonly used in additive manufacturing. Until now, the mechanical properties of the AM components could not be calculated or estimated until they've been assembled and checked. In this work, a novel approach is suggested as to how the extrusion process affects the mechanical properties of the printed component to obtain how the parts can be manufactured or printed to achieve improved mechanical properties. This methodology is based on an experimental procedure in which the combination of parameters to achieve an optimal from a manufacturing experiment and its value can be determined, the results obtained show the effect of the extrusion process affects the mechanical properties.

CubeSat Fabrication through Additive Manufacturing and Micro-Dispensing

2011 ◽  
Vol 2011 (1) ◽  
pp. 001021-001027 ◽  
Author(s):  
Cassie Gutierrez ◽  
Rudy Salas ◽  
Gustavo Hernandez ◽  
Dan Muse ◽  
Richard Olivas ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Computer Aided Design ◽  
Printed Circuit Boards ◽  
Fused Deposition Modeling ◽  
Integrated Approach ◽  
Layer By Layer ◽  
New Paradigm ◽  
Spatial Gradients ◽  
Fused Deposition ◽  
On Demand

Fabricating entire systems with both electrical and mechanical content through on-demand 3D printing is the future for high value manufacturing. In this new paradigm, conformal and complex shapes with a diversity of materials in spatial gradients can be built layer-by-layer using hybrid Additive Manufacturing (AM). A design can be conceived in Computer Aided Design (CAD) and printed on-demand. This new integrated approach enables the fabrication of sophisticated electronics in mechanical structures by avoiding the restrictions of traditional fabrication techniques, which result in stiff, two dimensional printed circuit boards (PCB) fabricated using many disparate and wasteful processes. The integration of Additive Manufacturing (AM) combined with Direct Print (DP) micro-dispensing and robotic pick-and-place for component placement can 1) provide the capability to print-on-demand fabrication, 2) enable the use of micron-resolution cavities for press fitting electronic components and 3) integrate conductive traces for electrical interconnect between components. The fabrication freedom introduced by AM techniques such as stereolithography (SL), ultrasonic consolidation (UC), and fused deposition modeling (FDM) have only recently been explored in the context of electronics integration and 3D packaging. This paper describes a process that provides a novel approach for the fabrication of stiff conformal structures with integrated electronics and describes a prototype demonstration: a volumetrically-efficient sensor and microcontroller subsystem scheduled to launch in a CubeSat designed with the CubeFlow methodology.

scholarly journals Ablative Laser Structuring for Stretchable Multilayer and Multi-Material Electronics and Sensor Systems

Proceedings ◽  
2020 ◽  
Vol 56 (1) ◽  
pp. 21
Author(s):  
Simon P. Stier ◽  
Holger Böse
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Fused Deposition Modeling ◽  
Selective Laser Sintering ◽  
Circuit Board ◽  
Circuit Boards ◽  
Thermoplastic Polymers ◽  
Digital Light Processing ◽  
Fused Deposition ◽  
Liquid Silicone

Conventional machining and shaping processes for polymers and elastomers such as injection molding exhibit significant disadvantages, as specific tools have to be manufactured, the method of machining is highly dependent on the material properties, and the cost of automation is usually high. Therefore, additive manufacturing processes (3D printing) have established themselves as an alternative. This eliminates the expensive production of tools and the production is individualized. However, the specific (additive) manufacturing process remains highly dependent on the properties of the material. These processes include selective laser sintering (SLS) for powdered thermoplastic polymers and metals, extrusion such as fused deposition modeling (FDM) for thermoplastic polymers in wire form, or optical curing such as digital light processing (DLP) for liquid resins. Especially for elastomer sensors or circuit boards (structure of several alternately constituted approx. 100 µm-thick elastomer films made with different types of liquid silicone rubber), there is no suitable additive manufacturing process that combines liquid, partly non-transparent source materials, multi-component printing, and very fine layer thicknesses. In order to enable a largely automated, computer-aided manufacturing process, we have developed the concept of ablative multilayer and multi-material laser-assisted manufacturing. Here, the layers (conductive and non-conductive elastomers, as well as metal layers for contacting) are first coated over the entire surface (e.g., spray, dip, or doctor blade coating, as well as galvanic coating) and then selectively removed with a CO2 or fiber laser. These steps are repeated several times to achieve a multi-layer structured design. Is it not only possible to adjust and improve the work previously carried out manually, but also to introduce completely new concepts, such as fine through-plating between the layers to enable much more compact structures to be possible. As an exemplary application, we have used the process for manufacturing a thin and surface solderable pressure sensor and a stretchable circuit board.

scholarly journals Curved Layer Fused Deposition Modeling in Conductive Polymer Additive Manufacturing

2011 ◽  
Vol 199-200 ◽  
pp. 1984-1987 ◽  
Author(s):  
Olaf Diegel ◽  
Sarat Singamneni ◽  
Ben Huang ◽  
Ian Gibson
Keyword(s):  
Additive Manufacturing ◽  
Printed Circuit Boards ◽  
Fused Deposition Modeling ◽  
Conductive Polymer ◽  
Fused Deposition ◽  
National University ◽  
Deposition Modeling ◽  
Plastic Components ◽  
Manufacturing Technologies ◽  
Plastic Parts

This paper describes a curved-layer additive manufacturing technology that has the potential to print plastic components with integral conductive polymer electronic circuits. Researchers at AUT University in New Zealand and the National University of Singapore have developed a novel Fused Deposition Modeling (FDM) process in which the layers of material that make up the part are deposited as curved layers instead of the conventional flat layers. This technology opens up possibilities of building curved plastic parts that have conductive electronic tracks and components printed as an integral part of the plastic component, thereby eliminating printed circuit boards and wiring. It is not possible to do this with existing flat-layer additive manufacturing technologies as the continuity of a circuit could be interrupted between the layers. With curved-layer fused deposition modeling (CLFDM) this problem is removed as continuous filaments in 3 dimensions can be produced, allowing for continuous conductive circuits.

scholarly journals Getting Rid of the Wires: Curved Layer Fused Deposition Modeling in Conductive Polymer Additive Manufacturing

2011 ◽  
Vol 467-469 ◽  
pp. 662-667 ◽  
Author(s):  
Olaf Diegel ◽  
Sarat Singamneni ◽  
Ben Huang ◽  
Ian Gibson
Keyword(s):  
Additive Manufacturing ◽  
Printed Circuit Boards ◽  
Fused Deposition Modeling ◽  
Conductive Polymer ◽  
Plastic Shell ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Plastic Components ◽  
Manufacturing Technologies ◽  
Plastic Parts

This paper describes an additive manufacturing technology that has the potential to print plastic components with integral conductive polymer electronic circuits. This could have a major impact in the fields of robotics and mechatronics as it has the potential to allow large wiring looms, often an issue with complex robotic systems, to be printed as an integral part of the products plastic shell. This paper describes the development of a novel Fused Deposition Modeling (FDM) process in which the layers of material that make up the part are deposited as curved layers instead of the conventional flat layers. This opens up possibilities of building curved plastic parts that have conductive electronic tracks and components printed as an integral part of the plastic component, thereby eliminating printed circuit boards and wiring. It is not possible to do this with existing flatlayer additive manufacturing technologies as the continuity of a circuit could be interrupted between the layers. With curved-layer fused deposition modeling (CLFDM) this problem is removed as continuous filaments in 3 dimensions can be produced, allowing for continuous conductive circuits.

scholarly journals Carbon Nanotube-Based Composite Filaments for 3D Printing of Structural and Conductive Elements

2021 ◽  
Vol 11 (3) ◽  
pp. 1272
Author(s):  
Bartłomiej Podsiadły ◽  
Piotr Matuszewski ◽  
Andrzej Skalski ◽  
Marcin Słoma
Keyword(s):  
Carbon Nanotubes ◽  
Fused Deposition Modeling ◽  
Supply Voltage ◽  
Acrylonitrile Butadiene Styrene ◽  
Structural Elements ◽  
Filling Fraction ◽  
Fused Deposition ◽  
Structural Electronics ◽  
Measured Sample ◽  
Deposition Modeling

In this publication, we describe the process of fabrication and the analysis of the properties of nanocomposite filaments based on carbon nanotubes and acrylonitrile butadiene styrene (ABS) polymer for fused deposition modeling (FDM) additive manufacturing. Polymer granulate was mixed and extruded with a filling fraction of 0.99, 1.96, 4.76, 9.09 wt.% of CNTs (carbon nanotubes) to fabricate composite filaments with a diameter of 1.75 mm. Detailed mechanical and electrical investigations of printed test samples were performed. The results demonstrate that CNT content has a significant influence on mechanical properties and electrical conductivity of printed samples. Printed samples obtained from high CNT content composites exhibited an improvement in the tensile strength by 12.6%. Measurements of nanocomposites’ electrical properties exhibited non-linear relation between the supply voltage and measured sample resistivity. This effect can be attributed to the semiconductor nature of the CNT functional phase and the occurrence of a tunnelling effect in percolation network. Detailed I–V characteristics related to the amount of CNTs in the composite and the supply voltage influence are also presented. At a constant voltage value, the average resistivity of the printed elements is 2.5 Ωm for 4.76 wt.% CNT and 0.15 Ωm for 9.09 wt.% CNT, respectively. These results demonstrate that ABS/CNT composites are a promising functional material for FDM additive fabrication of structural elements, but also structural electronics and sensors.

scholarly journals Automated Testing and Characterization of Additive Manufacturing (ATCAM)

2021 ◽  
Author(s):  
Arash Alex Mazhari ◽  
Randall Ticknor ◽  
Sean Swei ◽  
Stanley Krzesniak ◽  
Mircea Teodorescu
Keyword(s):  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Cell System ◽  
Automated Testing ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Machine Calibration

AbstractThe sensitivity of additive manufacturing (AM) to the variability of feedstock quality, machine calibration, and accuracy drives the need for frequent characterization of fabricated objects for a robust material process. The constant testing is fiscally and logistically intensive, often requiring coupons that are manufactured and tested in independent facilities. As a step toward integrating testing and characterization into the AM process while reducing cost, we propose the automated testing and characterization of AM (ATCAM). ATCAM is configured for fused deposition modeling (FDM) and introduces the concept of dynamic coupons to generate large quantities of basic AM samples. An in situ actuator is printed on the build surface to deploy coupons through impact, which is sensed by a load cell system utilizing machine learning (ML) to correlate AM data. We test ATCAM’s ability to distinguish the quality of three PLA feedstock at differing price points by generating and comparing 3000 dynamic coupons in 10 repetitions of 100 coupon cycles per material. ATCAM correlated the quality of each feedstock and visualized fatigue of in situ actuators over each testing cycle. Three ML algorithms were then compared, with Gradient Boost regression demonstrating a 71% correlation of dynamic coupons to their parent feedstock and provided confidence for the quality of AM data ATCAM generates.

scholarly journals Implementation of Fused Filament Fabrication in Dentistry

2021 ◽  
Vol 11 (14) ◽  
pp. 6444
Author(s):  
Jörg Lüchtenborg ◽  
Felix Burkhardt ◽  
Julian Nold ◽  
Severin Rothlauf ◽  
Christian Wesemann ◽  
...  
Keyword(s):  
Fused Deposition Modeling ◽  
Present Report ◽  
Cost Effective ◽  
Great Promise ◽  
Temperature Sensitive ◽  
Fused Filament Fabrication ◽  
Digital Light Processing ◽  
Fused Deposition ◽  
Surgical Guides ◽  
Novel Approach

Additive manufacturing is becoming an increasingly important technique for the production of dental restorations and assistive devices. The most commonly used systems are based on vat polymerization, e.g., stereolithography (SLA) and digital light processing (DLP). In contrast, fused filament fabrication (FFF), also known under the brand name fused deposition modeling (FDM), is rarely applied in the dental field. This might be due to the reduced accuracy and resolution of FFF compared to vat polymerization. However, the use of FFF in the dental sector seems very promising for in-house production since it presents a cost-effective and straight forward method. The manufacturing of nearly ready-to-use parts with only minimal post-processing can be considered highly advantageous. Therefore, the objective was to implement FFF in a digital dental workflow. The present report demonstrates the production of surgical guides for implant insertion by FFF. Furthermore, a novel approach using a temperature-sensitive filament for bite registration plates holds great promise for a simplified workflow. In combination with a medical-grade filament, a multi-material impression tray was printed for optimized impression taking of edentulous patients. Compared to the conventional way, the printed thermoplastic material is pleasant to model and can allow clean and fast work on the patient.

Design, Development and Characterization of Linear, Soft Actuators via Additive Manufacturing

2018 ◽  
Author(s):  
Alfonso Costas ◽  
Daniel E. Davis ◽  
Yixian Niu ◽  
Sadegh Dabiri ◽  
Jose Garcia ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Fused Deposition Modeling ◽  
Single Step ◽  
Design Development ◽  
Initial Attempt ◽  
Fused Deposition ◽  
Piston Cylinder ◽  
Compact Size ◽  
Soft Actuators

Additive manufacturing has emerged as an alternative to traditional manufacturing technologies. In particular, industries like fluid power, aviation and robotics have the potential to benefit greatly from this technology, due to the design flexibility, weight reduction and compact size that can be achieved. In this work, the design process and advantages of using 3D printing to make soft linear actuators were studied and highlighted. This work explored the limitations of current additive manufacturing tolerances to fabricate a typical piston-cylinder assembly, and how enclosed bellow actuators could be used to overcome high leakage and friction issues experienced with a piston-cylinder type actuator. To do that, different 3D printing technologies were studied and evaluated (stereolithorgraphy and fused deposition modeling) in the pursuit of high-fidelity, cost-effective 3D printing. The initial attempt consisted of printing the soft actuators directly using flexible materials in a stereolithography-type 3D printer. However, these actuators showed low durability and poor performance. The lack of a reliable resin resulted in the replacement of this material by EcoFlex® 00-30 silicone and the use of a 3D printed mold to cast the actuators. These molds included a 3-D printed dissolvable core inside the cast actuator in order to finish the manufacturing process in one single step. An experimental setup to evaluate the capabilities of these actuators was developed. Results are shown to assess the steady-state and the dynamic characteristics of these actuators. These tests resulted into the stroke-pressure and stroke-time responses for a specific load given different proportional valve inputs.

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