Consolidation phenomena in laser and powder-bed based layered manufacturing

New microproducts need the utilization of a diversity of materials and have complicated three-dimensional (3D) microstructures with high aspect ratios. To date, many micromanufacturing processes have been developed but specific class of such processes are applicable for fabrication of functional and true 3D microcomponents/assemblies. The aptitude to process a broad range of materials and the ability to fabricate functional and geometrically complicated 3D microstructures provides the additive manufacturing (AM) processes some profits over traditional methods, such as lithography-based or micromachining approaches investigated widely in the past. In this paper, 3D micro-AM processes have been classified into three main groups, including scalable micro-AM systems, 3D direct writing, and hybrid processes, and the key processes have been reviewed comprehensively. Principle and recent progress of each 3D micro-AM process has been described, and the advantages and disadvantages of each process have been presented.

/pdf/a-review-on-3d-micro-additive-manufacturing-technologies-1kbpeb2xb5.pdf

A review on 3D micro-additive manufacturing technologies

Additive manufacturing (AM) is a technology which has the potential not only to change the way of conventional industrial manufacturing processes, adding material instead of subtracting, but also to create entirely new production and business strategies. Since about three decades, AM technologies have been used to fabricate prototypes or models mostly from polymeric or metallic materials. Recently, products have been introduced into the market that cannot be produced in another way than additively. Ceramic materials are, however, not easy to process by AM technologies, as their processing requirements (in terms of feedstock and/or sintering) are very challenging. On the other hand, it can be expected that AM technologies, once successful, will have an extraordinary impact on the industrial production of ceramic components and, moreover, will open for ceramics new uses and new markets.

Additive Manufacturing of Ceramics: Issues, Potentialities, and Opportunities

Interest in multifunctional structures made automatically from multiple materials poses a challenge for today's additive manufacturing (AM) technologies; however the ability to process multiple materials is a fundamental advantage to some AM technologies. The capability to fabricate multiple material parts can improve AM technologies by either optimising the mechanical properties of the parts or providing additional functions to the final parts. The objective of this paper is to give an overview on the current state of the art of multiple material AM technologies and their practical applications. In this paper, multiple material AM processes have been classified and the principles of the key processes have been reviewed comprehensively. The advantages and disadvantages of each process, recent progress, challenging technological obstacles, the possible strategies to overcome these barriers, and future trends are also discussed.

Multiple material additive manufacturing – Part 1: a review

Most existing methods for additive manufacturing (AM) of metals are inherently limited to ~20–50 μm resolution, which makes them untenable for generating complex 3D-printed metallic structures with smaller features We developed a lithography-based process to create complex 3D nano-architected metals with ~100 nm resolution We first synthesize hybrid organic–inorganic materials that contain Ni clusters to produce a metal-rich photoresist, then use two-photon lithography to sculpt 3D polymer scaffolds, and pyrolyze them to volatilize the organics, which produces a >90 wt% Ni-containing architecture We demonstrate nanolattices with octet geometries, 2 μm unit cells and 300–400-nm diameter beams made of 20-nm grained nanocrystalline, nanoporous Ni Nanomechanical experiments reveal their specific strength to be 21–72 MPa g^(−1) cm^3, which is comparable to lattice architectures fabricated using existing metal AM processes This work demonstrates an efficient pathway to 3D-print micro-architected and nano-architected metals with sub-micron resolution

/pdf/additive-manufacturing-of-3d-nano-architected-metals-3blsxc2uxh.pdf

Additive manufacturing of 3D nano-architected metals

Purpose – The purpose of the paper is the elucidation of certain mechanisms of laser material processing in general and laser micro sintering in particular. One major intention is to emphasize the synergism of the various effects of q‐switched laser pulses upon metal and ceramic powder material and to point out the non‐equilibrium character of reaction steps.Design/methodology/approach – Recent results and observations, obtained in development of “laser micro sintering,” are surveyed and analyzed. By breaking down the overall process into relevant steps and considering their possible kinetics, an approach is made towards interpreting specific phenomena of laser micro sintering. Thermodynamics upon heating of the material as well as its photo‐electronic response to the incident radiation are considered.Findings – The findings corroborate a model whereby short pulses of high intensity provide non‐equilibrium pressure conditions at the location of incidence, that allow for the melting of metal powder with an...

/pdf/principles-of-laser-micro-sintering-t5nphufu6d.pdf

Principles of Laser Micro Sintering

Purpose – Examples are given for the technical applicability of a novel development of selective laser sintering called “laser micro sintering”.Design/methodology/approach – Together with a specific method to produce powder layers, the controlled application of pulsed radiation for the processing of sub‐μm grained metal powders was exploited to produce micro‐tools with a heretofore unattained structural resolution.Findings – High resolution micro bodies are displayed. Instruments could be generated which proved to fulfil their designation as grip bits for micro manipulators. The micro‐bodies can be generated detachably from or firmly fixed to the construction substrate. The material of the generated bodies withstands the traction forces when used as an injection mold for polymer casts.Research limitations/implications – Densities and structural resolutions can still be improved especially with a newly updated version of the equipment. Laser micro sintering of materials, other than metal (e.g. ceramics), h...

Industrial freeform generation of microtools by laser micro sintering

As mechanical engineering industry encounters a growing demand of µm-sized or µm-structured components for an increasing range of applications, miniaturization is presently ranking among the most important goals in product and tool development.Compared to still higher resolving techniques, selective laser sintering (SLS) still bears the advantages of relatively low production cost and short processing times even for series productions of micro parts. Furthermore, next to prismatic or tapered microstructures, undercuts and hollows can be realized.Until recently commercial SLS units were unable to generate micro parts smaller than 100 µm. A novel modification of SLS together with a new setup, developed by Laser Institut Mittelsachsen e.V, extends the resolution to less than 30 µm with a minimal roughness of 1.5µm. The technique has been upgraded and successfully applied to produce micro tools or micro-components for tools from powders of refractory as well as lower melting metals in steps of 1µm thick sintered layers.Based on this process and device, 3D-Micromac AG (Chemnitz, Germany) launches into the market a commercial system, which, on an industrial scale, performs selective laser sintering of solid and structured metal and in future also ceramic parts.As mechanical engineering industry encounters a growing demand of µm-sized or µm-structured components for an increasing range of applications, miniaturization is presently ranking among the most important goals in product and tool development.Compared to still higher resolving techniques, selective laser sintering (SLS) still bears the advantages of relatively low production cost and short processing times even for series productions of micro parts. Furthermore, next to prismatic or tapered microstructures, undercuts and hollows can be realized.Until recently commercial SLS units were unable to generate micro parts smaller than 100 µm. A novel modification of SLS together with a new setup, developed by Laser Institut Mittelsachsen e.V, extends the resolution to less than 30 µm with a minimal roughness of 1.5µm. The technique has been upgraded and successfully applied to produce micro tools or micro-components for tools from powders of refractory as well as lower melting metals in steps of 1µm thick sinte...

Industrial laser micro sintering

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Principles of Laser Micro Sintering

Industrial freeform generation of microtools by laser micro sintering

Industrial laser micro sintering