Proprietary metal 3D printing is still relegated to relatively expensive systems that have been constructed over years of expensive trial-and-error to obtain optimum 3D printing settings.Low-cost open-source metal 3D ...Proprietary metal 3D printing is still relegated to relatively expensive systems that have been constructed over years of expensive trial-and-error to obtain optimum 3D printing settings.Low-cost open-source metal 3D printers can potentially democratize metal additive manufacturing;however,significant resources are required to redevelop optimal printing parameters for each metal on new machines.In this study,the particle swam optimization(PSO)experimenter,a free and open-source software package,is utilized to obtain the optimal printing parameters for a tungsten inert gas-based metal open source 3D printer.The software is a graphical user interface implementation of the PSO method and is designed specifically for hardware-in-loop testing.It uses the input of experimental variables and their respective ranges,and then proposes iterations for experiments.A custom fitness function is defined to characterize the experimental results and provide feedback to the algorithm for low-cost metal additive manufacturing.Four separate trials are performed to determine the optimal parameters for 3D printing.First,an experiment is designed to deposit and optimize the parameters for a single line.Second,the parameters for a single-layer plane is optimized experimentally.Third,the optimal printing parameters for a cube is determined experimentally.Fourth,the line optimization experiment is revised and reconducted using different shield gas parameters.The results and limitations are presented and discussed in the context of expanding wire arc additive manufacturing to more systems and material classes for distributed digital manufacturing.展开更多
Microscale metallic structures enhanced by additive manufacturing technology have attracted extensive attention especially in microelectronics and electromechanical devices.Meniscus-confined electrodeposition(MCED)adv...Microscale metallic structures enhanced by additive manufacturing technology have attracted extensive attention especially in microelectronics and electromechanical devices.Meniscus-confined electrodeposition(MCED)advances microscale 3D metal printing,enabling simpler fabrication of superior metallic microstructures in air without complex equipment or post-processing.However,accurately predicting growth rates with current MCED techniques remain challenging,which is essential for precise structure fabrication and preventing nozzle clogging.In this work,we present a novel approach to electrochemical 3D printing that utilizes a self-adjusting,voxelated method for fabricating metallic microstructures.Diverging from conventional voxelated printing which focuses on monitoring voxel thickness for structure control,this technique adopts a holistic strategy.It ensures each voxel’s position is in alignment with the final structure by synchronizing the micropipette’s trajectory during deposition with the intended design,thus facilitating self-regulation of voxel position and reducing errors associated with environmental fluctuations in deposition parameters.The method’s ability to print micropillars with various tilt angles,high density,and helical arrays demonstrates its refined control over the deposition process.Transmission electron microscopy analysis reveals that the deposited structures,which are fabricated through layer-by-layer(voxel)printing,contain nanotwins that are widely known to enhance the material’s mechanical and electrical properties.Correspondingly,in situ scanning electron microscopy(SEM)microcompression tests confirm this enhancement,showing these structures exhibit a compressive yield strength exceeding 1 GPa.The indentation tests provided an average hardness of 3.71 GPa,which is the highest value reported in previous work using MCED.The resistivity measured by the four-point probe method was(1.95±0.01)×10^(−7)Ω·m,nearly 11 times that of bulk copper.These findings demonstrate the considerable advantage of this technique in fabricating complex metallic microstructures with enhanced mechanical properties,making it suitable for advanced applications in microsensors,microelectronics,and micro-electromechanical systems.展开更多
Based on the symmetric re-entrant honeycomb(S-RH)structure with negative Poisson’s ratios,a novel asymmetric and rotatable re-entrant honeycomb(AR-RH)structure was proposed.Both the S-RH structure and AR-RH structure...Based on the symmetric re-entrant honeycomb(S-RH)structure with negative Poisson’s ratios,a novel asymmetric and rotatable re-entrant honeycomb(AR-RH)structure was proposed.Both the S-RH structure and AR-RH structure were produced by the 3D printing technology.Through experimental test and finite element simulation,the deformation mechanism and energy absorption characteristics of the AR-RH structure and the S-RH structure with negative Poisson’s ratios at different impact velocities were compared.The experimental test and finite element simulation results show that the novel AR-RH structure with negative Poisson’s ratios has stronger energy absorption capacity than the S-RH structure,and it has been verified that the rotatability of AR-RH can indeed absorb energy.Furthermore,the degree of asymmetry of the AR-RH structure was discussed.展开更多
文摘Proprietary metal 3D printing is still relegated to relatively expensive systems that have been constructed over years of expensive trial-and-error to obtain optimum 3D printing settings.Low-cost open-source metal 3D printers can potentially democratize metal additive manufacturing;however,significant resources are required to redevelop optimal printing parameters for each metal on new machines.In this study,the particle swam optimization(PSO)experimenter,a free and open-source software package,is utilized to obtain the optimal printing parameters for a tungsten inert gas-based metal open source 3D printer.The software is a graphical user interface implementation of the PSO method and is designed specifically for hardware-in-loop testing.It uses the input of experimental variables and their respective ranges,and then proposes iterations for experiments.A custom fitness function is defined to characterize the experimental results and provide feedback to the algorithm for low-cost metal additive manufacturing.Four separate trials are performed to determine the optimal parameters for 3D printing.First,an experiment is designed to deposit and optimize the parameters for a single line.Second,the parameters for a single-layer plane is optimized experimentally.Third,the optimal printing parameters for a cube is determined experimentally.Fourth,the line optimization experiment is revised and reconducted using different shield gas parameters.The results and limitations are presented and discussed in the context of expanding wire arc additive manufacturing to more systems and material classes for distributed digital manufacturing.
基金supported in part by National Key R&D Program of China under Grant 2023YFB4705600in part by the National Natural Science Foundation of China under Grants 61925304,62127810 and 62203138+1 种基金in part by the National Postdoctoral Program for Innovative Talents under Grant BX20200107in part by the Self-Planned Task(No.SKLRS202205C)of State Key Laboratory of Robotics and System(HIT).
文摘Microscale metallic structures enhanced by additive manufacturing technology have attracted extensive attention especially in microelectronics and electromechanical devices.Meniscus-confined electrodeposition(MCED)advances microscale 3D metal printing,enabling simpler fabrication of superior metallic microstructures in air without complex equipment or post-processing.However,accurately predicting growth rates with current MCED techniques remain challenging,which is essential for precise structure fabrication and preventing nozzle clogging.In this work,we present a novel approach to electrochemical 3D printing that utilizes a self-adjusting,voxelated method for fabricating metallic microstructures.Diverging from conventional voxelated printing which focuses on monitoring voxel thickness for structure control,this technique adopts a holistic strategy.It ensures each voxel’s position is in alignment with the final structure by synchronizing the micropipette’s trajectory during deposition with the intended design,thus facilitating self-regulation of voxel position and reducing errors associated with environmental fluctuations in deposition parameters.The method’s ability to print micropillars with various tilt angles,high density,and helical arrays demonstrates its refined control over the deposition process.Transmission electron microscopy analysis reveals that the deposited structures,which are fabricated through layer-by-layer(voxel)printing,contain nanotwins that are widely known to enhance the material’s mechanical and electrical properties.Correspondingly,in situ scanning electron microscopy(SEM)microcompression tests confirm this enhancement,showing these structures exhibit a compressive yield strength exceeding 1 GPa.The indentation tests provided an average hardness of 3.71 GPa,which is the highest value reported in previous work using MCED.The resistivity measured by the four-point probe method was(1.95±0.01)×10^(−7)Ω·m,nearly 11 times that of bulk copper.These findings demonstrate the considerable advantage of this technique in fabricating complex metallic microstructures with enhanced mechanical properties,making it suitable for advanced applications in microsensors,microelectronics,and micro-electromechanical systems.
基金This work is supported by the State Key for Strength and Vibration of Mechanical Structures of Xi’an Jiaotong University(No.SV2018-KF-32)the Natural Science Foundation of Guangdong Province of China(2020A1515011064).
文摘Based on the symmetric re-entrant honeycomb(S-RH)structure with negative Poisson’s ratios,a novel asymmetric and rotatable re-entrant honeycomb(AR-RH)structure was proposed.Both the S-RH structure and AR-RH structure were produced by the 3D printing technology.Through experimental test and finite element simulation,the deformation mechanism and energy absorption characteristics of the AR-RH structure and the S-RH structure with negative Poisson’s ratios at different impact velocities were compared.The experimental test and finite element simulation results show that the novel AR-RH structure with negative Poisson’s ratios has stronger energy absorption capacity than the S-RH structure,and it has been verified that the rotatability of AR-RH can indeed absorb energy.Furthermore,the degree of asymmetry of the AR-RH structure was discussed.
