3D Bioplotter Research Papers

Additive manufacturing of objects with complex geometries from refractory metals remains very challenging. Here, we demonstrate the fabrication of tungsten sheet-gyroids via 3D ink-extrusion of WO3 nano-powder followed by hydrogen reduction and activated sintering with NiO additions, as an alternative route to beam-based additive manufacturing of tungsten and other high melting metals and alloys. The microstructure and mechanical properties of the tungsten sheet-gyroids are measured for various wall architectures and processing conditions. The original gyroid architecture, separating two equally-sized volumes, is modified to achieve double-wall gyroids (with three separate volumes) with higher relative densities. The compressive properties of these single-…

Microlattices with orthogonal 0-90° architecture are 3D-extrusion printed from inks containing a blend of oxide powders (Co3O4, CuO, Fe2O3, and NiO) and metal powder (Cr). Equiatomic CoCrCuFeNi microlattices with ∼170 µm diameter struts are then synthesized by H2-reduction of the oxides followed by sintering and interdiffusion of the resulting metals. These process steps are studied by in-situ synchrotron X-ray diffraction on single extruded microfilaments (lattice struts) with ∼250 µm diameter. After reduction and partial interdiffusion at 600 ˚C for 1 h under H2, filaments consist of lightly-sintered metallic particles with some unreduced Cr2O3. A reduced, nearly fully densified (porosity: 1.6 ± 0.7%)…

3D ink-extrusion of powders followed by sintering is an emerging additive manufacturing method capable of creating metallic microlattices. Here, we study the creation of hierarchically porous Fe or Ni scaffolds by 3D extrusion of 0/90° lattices from inks consisting of fine oxide powders (Fe2O3 or NiO, < 3 µm), coarse space-holder particles (CuSO4, < 45 µm) and a polymer binder within a solvent. After space-holder leaching and debinding of the lattices, a sintering step densifies the metallic Fe or Ni powders created by oxide reduction with H2, while maintaining the larger pores templated by the space-holder particles within the printed…

Cobalt-based superalloy microlattices were created via (i) three-dimensional-extrusion printing of inks containing a suspension of Co-, Ni- and W-oxide particles, (ii) H2-reduction of the oxides and sintering to a homogenous Co-Ni-W alloy, (iii) Al pack-cementation to deposit Al on the microlattice struts, followed by Al-homogenization. The resulting Co-(18–20)Ni-(5–6)W-(10–13)Al (at.%) microlattices, with 27–30% relative density and 350 μm diameter struts, display a peak in yield strength at 750°C, consistent with their γ/γ′ aged microstructure. Oxidation resistance is strongly improved compared to Al-free printed Co-Ni-W lattices, via the formation of an Al2O3 surface layer. However, the resulting Al depletion within the struts…

Cobalt-based superalloy microlattices with γ/γ′ microstructure are manufactured by combining two additive methods: ink-extrusion 3D-printing and pack-cementation surface alloying. First, a microlattice green structure is 3D-printed at ambient temperature from inks comprised of Co3O4, NiO, and WO3 powders, an elastomeric binder and solvents. Organic removal followed by oxide reduction under Ar-5% H2, sintering and homogenization at 1250 °C lead to a metallic microlattice with dense struts with uniform γ (fcc)-Co–22Ni–8W (at.%) composition. Second, aluminum is deposited on the strut surfaces via pack-cementation at 1000 °C, diffused at 1300 °C through the strut volume to achieve a uniform composition (Co–20Ni–6W–10Al or…

3D ink-extrusion of powders followed by sintering is an emerging alternative to beam-based additive manufacturing, capable of creating 3D metallic objects from 1D-extruded microfilaments. Here, in situ synchrotron X-ray diffraction and tomography are combined to study the phase evolution, alloy formation and sinter-densification of Fe-20Ni-5Mo (at.%) microfilaments. The filaments are

Additive manufacturing of high-entropy alloys combines the mechanical properties of this novel family of alloys with the geometrical freedom and complexity required by modern designs. Here, a non-beam approach to additive manufacturing of high-entropy alloys is developed based on 3D extrusion of inks containing a blend of oxide nanopowders (Co3O4 + Cr2O3 + Fe2O3 + NiO), followed by co-reduction to metals, inter-diffusion and sintering to near-full density CoCrFeNi in H2. A complex phase evolution path is observed by in-situ X-ray diffraction in extruded filaments when the oxide phases undergo reduction and the resulting metals inter-diffuse, ultimately forming face-centered-cubic equiatomic CoCrFeNi alloy. Linked to the phase evolution…

ungsten is of industrial relevance due its outstanding intrinsic properties (e.g., highest melting‐point of all elements) and therefore difficult to 3D‐print by conventional methods. Here, tungsten micro‐lattices are produced by room‐temperature extrusion‐based 3D‐printing of an ink comprising WO3–0.5%NiO submicron powders, followed by H2‐reduction and Ni‐activated sintering. The green bodies underwent isotropic linear shrinkage of ≈50% during the thermal treatment resulting in micro‐lattices, with overall 35–60% open‐porosity, consisting of 95–100% dense W–0.5%Ni struts having ≈80–300 μm diameter. Ball‐milling the powders and inks reduced the sintering temperature needed to achieve full densification from 1400 to 1200 °C and enabled the ink to be extruded…

Inks comprised of metallic Fe or Ni powders, an elastomeric binder, and graded volatility solvents are 3D-printed via syringe extrusion and sintered to form metallic cellular structures. Similar structures are created from Fe2O3 and NiO particle-based inks, with an additional hydrogen reduction step before sintering. All sintered structures exhibit 92–98% relative density within their struts, with neither cracking nor visible warping despite extensive volumetric shrinkage (≈70–80%) associated with reduction (for oxide powders) and sintering (for both metal and oxide powders). The cellular architectures, with overall relative densities of 32–49%, exhibit low stiffness (1–6 GPa, due to the particular architecture used), high…

A new method for complex metallic architecture fabrication is presented, through synthesis and 3D-printing of a new class of 3D-inks into green-body structures followed by thermochemical transformation into sintered metallic counterparts. Small and large volumes of metal-oxide, metal, and metal compound 3D-printable inks are synthesized through simple mixing of solvent, powder, and the biomedical elastomer, polylactic-co-glycolic acid (PLGA). These inks can be 3D-printed under ambient conditions via simple extrusion at speeds upwards of 150 mm s–1 into millimeter- and centimeter-scale thin, thick, high aspect ratio, hollow and enclosed, and multi-material architectures. The resulting 3D-printed green-bodies can be handled immediately, are…