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The primary objective of this study is to demonstrate the possibility of developing silica, alumina, and zircon-based photocurable ceramic suspensions that can be used for visible light photopolymerization (> 450 nm) and to optimise the binder formulations for the purpose of LCD-based ceramic 3D printing applications. Reference ceramic components for this work are ceramic cores employed in the investment casting of high-pressure turbine blades and vanes. Arguably, one of the most critical steps in photoinduced ceramic 3D printing is developing suitable ceramic suspensions, having high ceramic loading, low viscosity, and short curing times. Ceramic suspensions with four different novel binder formulations and commercial ceramic powders used in core manufacturing (SiO2, Al2O3 and ZrSiO4) were investigated to achieve the best trade-off between: (1) their curing performance (cure depth and curing speed), (2) rheological properties of the binder mixtures at the solid loadings of 60 vol.% for SiO2, 55 vol.% for ZrSiO4, and 45 vol.% for Al2O3; and (3) the green body mechanical properties of the mixtures after printing. The effect of ceramic particles on the selected binders was examined individually, and the correlation between cure depth (Cd), volumetric loading, and curing speed are evaluated. The results show all binders designed in this study provide an adequate cure depth, even at high ceramic loadings. When the curing behaviour of all unloaded binder mixtures from the previous study [ 1 ] compared with the 10 vol.% SiO2 loaded mixtures, the cure depth of all formulated binder mixtures increased 50–55 % and the curing thickness of 60 vol.% SiO2 loaded suspensions were still slightly higher than their unloaded counterparts. The rheology outcomes indicate that lower viscosity binders always result in lower viscosity of the ceramic loaded inks, even without taking the effect of dispersants into account. Besides, the addition of N-Vinyl-2-Pyrrolidone (NVP) monofunctional monomer to the binder mixtures significantly reduces the viscosity and changes the normally linear relationship of the mix viscosity and its silica loading content. Among the binder formulations loaded with 60 vol.% of SiO2, the formulation providing the lowest viscosity and highest mechanical property consists of 5 wt.% of NVP, 45 wt.% of HDDA and 50 wt.% of Photocentric 34 resin. Although this binder mixture showed the highest green flexural strength when loaded by 55 vol.% ZrSiO4, all other mixtures loaded with zircon flour also demonstrated a near-fluid behaviour, below 200 s−1. In Al2O3 loaded mixtures, the HDDA di-functional binder formulations present lowest viscosity and the di- and multifunctional monomer blends (HDDA-Photocentric27) showed the highest mechanical properties when used in a 50/50 ratio. This work summarises the best binder choices for silica, alumina and zircon based ceramic suspensions used in core printing for investment casting applications through LCD screen printing.

Additive manufacturing via direct ink writing and microwave dielectric characterisation of commercially produced low sintering temperature bismuth molybdenum oxide ceramics, have been both performed for the first time, following a powder-to-product holistic approach. We demonstrated that direct ink writing is an excellent candidate for producing dielectric substrates to be used for wireless telecommunication applications operating at microwave (MW) frequencies, with great repeatability and properties comparable to ceramics fabricated via conventional processing routes. The optimum density (relative density of ρr ≈ 93%) of the 3D printed test samples was obtained by sintering at 660 °C for 2 h, resulting in a relative permittivity er = 35.7, dielectric loss tanδ = 0.0004 and microwave quality factor Q × f = 14,928 GHz. Sintering at higher temperatures promoted a porosity increase due to mismatching grain growth mechanisms and phase decomposition, that collectively hindered the test samples’ microwave dielectric performance in terms of achievable relative permittivity (er) and dielectric loss (tanδ).

In the vat photopolymerisation 3D printing technique, the properties of the printed parts are highly dependent on the degree of conversion of the monomers. The mechanisms and advantages of vat photopolymerisation at elevated temperatures, or so called “hot lithography”, were investigated in this paper. Two types of photoresins, commercially used as highly accurate castable resins, with different structural and diluent monomers, were employed in this study. Samples were printed at 25 °C, 40 °C, and 55 °C. The results show that hot lithography can significantly enhance the mechanical and dimensional properties of the printed parts and is more effective when there is a diluent with a network Tg close to the print temperature. When processed at 55 °C, Mixture A, which contains a diluent with a network Tg = 53 °C, was more readily impacted by heat compared to Mixture B, whose diluent had a network Tg = 105. As a result, a higher degree of conversion, followed by an increased Tg of the diluents, and improvements in the tensile strength and dimensional stability of the printed parts were observed, which enhanced the outcomes of the prints for the intended application in investment casting of complex components used in the aero and energy sectors. In conclusion, the effectiveness of the hot lithography process is contained by a correlation between the process temperature and the characteristics of the monomers in the mixture.

Ultra-low sintering temperature silver molybdenum oxide (Ag2Mo2O7) ceramics have been printed using direct ink writing (a material extrusion additive manufacturing process) for the first time. An optimum densification conditions of 460 °C / 2 h was determined, resulting in relative permittivity, er = 13.45, dielectric loss, tanδ = 0.0005, microwave quality factor, Q × f = 17,056 GHz and the temperature coefficient of resonant frequency τf = −121 ppm/°C. The results were comparable to the dielectric properties of conventionally fabricated ceramics. A series of metal/ceramic antenna designs were produced via dual-printing and co-firing, to demonstrate the potential of Ag2Mo2O7, to be used as a co-firable dielectric material for functional integrated circuits and/or microwave RF devices through multi-material direct ink writing.

Two-photon polymerization direct laser writing (TPP DLW) is an emerging technology for producing advanced functional devices with complex three-dimensional (3D) micro-structures. Tremendous efforts have been devoted to developing two-photon polymerizable photo-sensitive nanocomposites with tailored properties. Light-induced reconfigurable smart materials such as liquid crystalline elastomers (LCEs) are promising materials. However, due to the difficulties in designing two-photon polymerizable liquid crystal monomer (LCM) nanocomposite photoresists, it is challenging to fabricate true 3D LCE micro-structures. In this paper, we report the preparation of photo-sensitive LCE nanocomposites containing photothermal nanomaterials, including multiwalled carbon nanotubes, graphene oxide and gold nanorods (AuNRs), for TPP DLW. The printability of the LCE nanocomposites is assessed by the fidelity of the micro-structures under different laser writing conditions. DLW of GO/LCM photoresist has shown a vigorous bubble formation. This may be due to the excessive heat generation upon rapid energy absorption of 780 nm laser energy. Compared to pure LCM photoresists, AuNR/LCM photoresists have a lower laser intensity threshold and higher critical laser scanning speed, due to the high absorption of AuNRs at 780 nm, which enhanced the photo-sensitivity of the photoresist. Therefore, a shorter printing time can be achieved for the AuNR/LCM photoresist.

The material properties and processing of investment casting patterns manufactured using conventional wax injection Molding and those manufactured by vat photopolymerization can be substantially different in terms of thermal expansion and mechanical properties, which can generate problems with dimensional accuracy and stability before and during ceramic shelling and shell failures during the burn-out of the 3D printed casting patterns. In this paper and for the first time, the monofunctional Acryloyl morpholine monomer was used for 3D printing of casting patterns, due to its thermoplastic-like behavior, e.g., softening by heat. However, the hydrophilic behavior of this polymer led to an incorporation of up to 60 wt% of Hexanediol diacrylate, to control the water absorption of the network, which to some extent, compromised the softening feature of Acryloyl morpholine. Addition of a powdered wax filler resulted in a delayed thermal decomposition of the polymer network, however, it helped to reduce the thermal expansion of the parts. The dimensional accuracy and stability of the wax-filled formulation indicated an excellent dimensional tolerance of less than ±130 µm. Finally, the 3D printed patterns successfully went through a burn out process with no damages to the ceramic shell.

Additive manufacturing (AM), commonly known as 3D printing, is a family of novel and advanced manufacturing techniques that operate in a layer-by-layer additive manner and, by using a vast material palette, can deliver parts in an autonomous fashion directly from computer data without the need for additional tooling and with part complexities beyond most conventional manufacturing techniques. Serving under the in situ resource utilization concept, AM is envisioned as a highly promising solution for producing a range of physical assets off-world, by using as feedstock the abundant natural resources that are readily available onsite, from building life-sustaining habitats on the Moon or Mars, to fabricating various replacements parts, aiming to support human (or robotic) space exploration. This chapter discusses AM within a future planetary manufacturing scenario. It reviews those identified and prospective material space resources with a focus on lunar regolith, their simulants, and envisaged processing methods. Finally, a laser-based AM approach for fabricating parts using lunar regolith is presented and further discussed, as it shows great promise and showcases the potential of the technology.

Conventional planar frequency selective surfaces (FSSs) are characterized in the far-field region and they are sensitive to the incidence angle of impinging waves. In this paper, a spherical dome FSS is presented, aiming to provide improved angular stable bandpass filtering performance as compared to its planar counterpart when the FSS is placed in the near-field region of an antenna source. A comparison between the conformal FSS and a finite planar FSS is presented through simulations at the frequency range between 26 to 40 GHz in order to demonstrate the advantages of utilizing the conformal FSS in the near-field. The conformal FSS is 3D printed and copper electroplated, which leads to a low-cost and lightweight bandpass filter array. Placing it in the near-field region of a primary antenna can be used as radomes to realize compact high-performance mm-wave systems. The comparison between simulated and measured conformal FSS results is in good agreement. The challenges that arise when designing, manufacturing, and measuring this type of structure are reported and guidelines to overcome these are presented.

Selective laser melting is a promising additive manufacturing technology for manufacturing porous metallic bone scaffolds. Bone repair requires scaffolds that meet various mechanical and biological requirements. This paper addresses this challenge by comprehensively studying the performance of porous scaffolds. The main novelty is exploring scaffolds with different porosities, verifying various aspects of their performance and revealing the effect of their permeability on cell growth. This study evaluates the manufacturability, mechanical behaviour, permeability and biocompatibility of gyroid scaffolds. In simulations, mechanical behaviour and permeability exhibited up to 56% and 73% accuracy, respectively, compared to the experimental data. The compression and permeability experiments showed that the elastic modulus and the permeability of the scaffolds were both in the range of human bones. The morphological experiment showed that manufacturing accuracy increased with greater designed porosity, while the in vitro experiments revealed that permeability played the main role in cell proliferation. The significance of this work is improving the understanding of the effect of design parameters on the mechanical properties, permeability and cell growth of the scaffolds, which will enable the design of porous bone scaffolds with better bone-repair effects.

Herein, the cytotoxicity of a novel zwitterionic sulfobetaine hydrogel system with a nano-clay crosslinker has been investigated. We demonstrate that careful selection of the composition of the system (monomer to Laponite content) allows the material to be formed into controlled shapes using an extrusion based additive manufacturing technique with the ability to tune the mechanical properties of the product. Moreover, the printed structures can support their own weight without requiring curing during printing which enables the use of a printing-then-curing approach. Cell culture experiments were conducted to evaluate the neural cytotoxicity of the developed hydrogel system. Cytotoxicity evaluations were conducted on three different conditions; a control condition, an indirect condition (where the culture medium used had been in contact with the hydrogel to investigate leaching) and a direct condition (cells growing directly on the hydrogel). The result showed no significant difference in cell viability between the different conditions and cells were also found to be growing on the hydrogel surface with extended neurites present.

Fused filament fabrication (FFF) is a continuously growing additive manufacturing technology that aside from physical prototypes can also deliver functional prototypes and devices for radiofrequency (RF) and microwave applications. The very recent introduction of high-permittivity filaments for FFF has been one of the main facilitators for this major advancement, aiding microwave engineers to realise academics concepts that have thus far been impossible to fabricate and therefore invent new designs. However, the value to the RF community of these devices depends on accurate knowledge and repeatability of the electromagnetic properties of the materials being used which strongly relies on the processing strategy used during printing. This paper investigates the use of a high-permittivity filament and studies the impact of layer height and infill density on the relative permittivity (er) and loss tangent (tanδ). A maximum relative permittivity of er = 9.63 ± 0.16 and tanδ = 0.003 ± 0.0003 was achieved with a 200 μm layer thickness and 100% infill density. Finally, the results of this study are used in designing, simulating, 3D printing and measuring the performance of a novel graded-index dielectric lens operating at 10 GHz.

Additive manufacturing and its related techniques have frequently been put forward as a promising candidate for planetary in-situ manufacturing, from building life-sustaining habitats on the Moon to fabricating various replacements parts, aiming to support future extra-terrestrial human activity. This paper investigates the mechanical behaviour of lunar regolith simulant material components, which is a potential future space engineering material, manufactured by a laser-based powder bed fusion additive manufacturing system. The influence of laser energy input during processing was associated with the evolution of component porosity, measured via optical and scanning electron microscopy in combination with gas expansion pycnometry. The compressive strength performance and Vickers micro-hardness of the components were analysed and related back to the processing history and resultant microstructure of the lunar regolith simulant build material. Fabricated structures exhibited a relative porosity of 44–49% and densities ranging from 1.76 to 2.3 g cm−3, with a maximum compressive strength of 4.2 ± 0.1 MPa and elastic modulus of 287.3 ± 6.6 MPa, the former is comparable to a typical masonry clay brick (3.5 MPa). The additive manufacturing parts also had an average hardness value of 657 ± 14 HV0.05/15, better than borosilicate glass (580 HV). This study has shed significant insight into realising the potential of a laser-based powder bed fusion additive manufacturing process to deliver functional engineering assets via in-situ and abundant material sources that can be potentially used for future engineering applications in aerospace and astronautics.

Ultrasonic additive manufacturing (UAM) is a low temperature manufacturing method capable of embedding printed electronics in metal components. The effect of UAM processing on the resistivity of conductive tracks printed with five different conductive pastes based on silver, copper or carbon flakes/particles in either a thermoplastic or thermoset filler binder are investigated. For all but the carbon-based paste, the resistivity changed linearly with the UAM energy input. After UAM processing, a resistivity increase of more than 150 times was recorded for the copper based thermoset paste. The silver based pastes showed a resistivity increase of between 1.1 and 50 times from their initial values. The carbon-based paste showed no change in resistivity after UAM processing. Focussed ion beam microstructure analysis of the printed conductive tracks before and after UAM processing showed that the silver particles and flakes in at least one of the pastes partly dislodged from their thermoset filler creating voids, thereby increasing the resistivity, whereas the silver flakes in a thermoplastic filler did not dislodge due to material flow of the polymer binder. The lowest resistivity (8 × 10−5 Ω cm) after UAM processing was achieved for a thermoplastic paste with silver flakes at low UAM processing energy.

The primary focus of this study is to offer guidelines for developing binder formulations for visible light photoinduced ceramic 3D printing applications. Different monomer combinations with a variety of functional groups were mixed at various ratios to systematically study their rheological and curing behaviour, and mechanical properties (ultimate tensile strength, elongation at break, Young’s modulus). The optimum ratios of monomer blends were investigated by adjusting the balance of difunctional monomers (HDDA and Photocentric 27) and multifunctional monomers (tri- and tetrafunctional - PPTTA, Photocentric 34 and PE(EO)nTTA) at the weight rates of 20:80, 40:60, 50:50, 60:40, 70:30 and 80:20. The key curing parameters (penetration depth Dp and critical exposure energy Ec) were calculated by fitting values based on curing thickness (Cd), using Jacobs' Basic Working Curve Equation, to estimate optimum printing exposure time for each mixture. Although the curing performance of the mixtures was enhanced by increasing the functionality and molecular weight of the monomers in the mixture, the best viscosity and mechanical properties were obtained when difunctional monomers were mixed with a trifunctional (meth)acrylates. Two types of difunctional monomers were used in the mixtures and showed a similar performance. The best ratio between di- and trifunctional monomers were 50:50 and 40:60 wt ratios, yielding the best mechanical properties and minimum viscosity required for ceramic slurry mixtures. Moreover, the effect of vinyl-based monofunctional monomers as reactive diluents as well as hexa-functional monomers as cross-linkers on the shortlisted formulations was studied. This work summarises the best binder base choices for the daylight curable ceramic suspensions, used in LCD screen printing applications, and further works mcust be done to find the best debinding cycles.

Additive manufacturing (AM) has become more important and common in recent years. Advantages of AM include the ability to rapidly design and fabricate samples much faster than traditional manufacturing processes and to create complex internal geometries. Materials are crucial components of microwave systems and proper and accurate measurement of their dielectric properties is important to aid a high level of accuracy in design. There are numerous measurement techniques and finding the most appropriate method is important and requires consideration of all different factors and limitations. One limitation of sample preparation is that the sample size needs to fit in the measurement method. By utilizing the advantage of additive manufacturing, the material can be characterized using different measurement methods. In this paper, the additive manufacturing process and dielectric measurement methods have been critically reviewed. The test specimens for measuring dielectric properties were fabricated using fused filament fabrication (FFF)-based additive manufacturing and were measured using four different commercial dielectric properties measurement instruments including split post dielectric resonator (SPDR), rectangular waveguide, TE01δ cavity resonator, and open resonator. The measured results from the four techniques have been compared and have shown reasonable agreement with measurements within a 10 percent range.

This paper presents several demonstrators that utilize advanced additive manufacturing (AM) to rapidly prototype antennas, RF components for microwave and mm-wave applications. Antenna substrates with tailored permittivity; lenses, reflectarray with locally varied dielectric properties; and metamaterials can be fabricated by using extrusion based AM processes such as fused filament fabrication method to realize high gain antenna systems with low material cost, time-saving and low impact to the environment.

The development, fabrication, and production of scaffolds that help in the regurgitation of tissues are significant setbacks in the world of tissue engineering. Therefore, This research analyses the potential development of scaffold reinforced with primitive and gyroid lattice of a poly(lactic acid) (PLA), calcium hydroxyapatite (cHAP) and Reduce Graphene Oxide (rGO) into new composite materials with superior mechanical properties for a bone implant. The biomaterial composites and lattice structure mimics bone structure and materials through gradual dissemination of interconnected PLA, cHAP and rGO materials into the 3D printer. Assessment and nano-structural analysis of the biodegradable composite was carried out, using surface roughness evaluation, mechanical and bioactivity analysis tests for the structure. The results show evidence that the scaffolds exhibited a quite high porosity level, with uniformity in the distribution of cHAP and rGO particles. The results obtained from in-vitro tests showed that the PLA/cHAP/rGO scaffolds were non-toxic with good biocompatibility and biodegradability. These results indicate that PLA/cHAP/rGO could provide improved osseointegration while maintaining the structural integrity of bone necessary for orthopaedic applications. Hence, the present study demonstrated that the PLA/cHAP/rGO scaffolds have a potential application in bone Implant.

Polydimethylsiloxane (PDMS) materials are widely adopted in the manufacture of facial prostheses, lab-on-chip devices and scaffolds for soft-tissue engineering applications; however, their processing by additive manufacturing (AM) has proved challenging. Liquid silicone rubbers (LSRs) are favoured for their high shape fidelity when cast, but their low viscosity and surface tension often prevent self-support, post-extrusion. Poly(ether) ether ketone (PEEK) particle reinforcement through interfacial bonding has proven to enhance key properties of PDMS, expanding their end-use functionality. Still, the impact of such particles on the printability of LSR-PDMS is not explored. In this study, for the first time, solvent-free biocompatible PDMS-PEEK composites (up to 30 wt% PEEK) were successfully characterised for material extrusion (ME) printing. Rheological analysis confirmed shear-thinning of all PDMS-PEEK composites under applied load (within the tolerances of the printer) and dominant storage moduli at rest (i.e. prints can self-support), considered highly desirable for ME-based printing. Attained rheological datasets were used to guide initial printability studies, which revealed finer track fidelity with rising fractional content of PEEK, at comparable print speed and displacement values. Composites with higher PEEK content demonstrated significant increases in Shore A hardness and stiffness (in tension and compression) in bulk form. Last but not least, enhanced shape fidelity (thanks to PEEK reinforcement) and geometrical autonomy further expanded the manufacturing freedom of PDMS, whereby infill density could be controlled in order to increase the range of mechanical performance, previously unachievable with conventional casting fabrication. Fundamentally, this could lead to the manufacture of bespoke spatially graded multi-material structures and devices that could be used to replicate the heterogenous properties of soft human tissues and in other advanced material applications.

Low sintering temperature, ultra-low loss microwave ceramics are envisaged as future dielectrics for fabricating low temperature co-fired ceramic (LTCC) components for 5G applications. Low sintering temperature bismuth molybdate β-Bi2Mo2O9 ceramic powders have been synthesised using a solid-state reaction method. Their additive manufacture and resulting microwave properties are reported for the first time. Optimum densification occurred for 3D printed samples sintered 4 hours at 670°C which resulted in a maximum relative density (ρr) of 92%, relative permittivity (er) of 34, dielectric loss (tanδ) of 0.0007, giving a microwave quality factor (Qxf) of 10,050 GHz, properties attractive for LTCC applications.

Metallic and semiconductor nanowires can provide dramatically increased electrical and optical properties in a wide range of fields, ranging from photovoltaics to sensors and catalysts. In this research, a rapid manufacturing process has been developed for printing indium tin oxide microparticles and converting them into nanowires. Microparticle indium tin oxide (ITO) inks were formulated and printed. These were then converted into hierarchical nanowire films via laser irradiation (980 nm, NIR) with raster speeds of 40 mm s−1 in air, much faster compared to traditional manufacturing processes. For a 4 cm2 film, only 40 s of processing were required. A full materials characterization was performed on the materials pre and post laser processing with the most probable conversion mechanism found to be a laser induced carbothermal reduction process. Microstructural, chemical, and crystallographic evidence of the laser induced carbothermal reduction process were derived from SEM, XRD, XPS and TEM analysis. Compared to conventionally heat-treated printed samples, laser processing was found to increase the conductivity of the printed ITO from 0.88% to 40.47% bulk conductivity. This research demonstrates the ability of printing and laser processing to form nanowires in a high-speed manufacturing context, thereby enabling the development of printed non-transparent ITO nanowire electronics and devices.

A UV-curable nanoclay-zwitterionic hydrogel is synthesised and evaluated though rheological and mechanical testing. The results show that aging time of the pre-gel has a big impact on storage and loss of modulus which both increases with increasing aging time, particularly in the first 48 h. The pre-gel is successfully printed and is shown to be able to support itself making it possible to fully print structures before curing. Compression and tensile samples are printed and compared to cast samples. The pre-gel aging time showed that an increased time resulted in a lower strain at failure for both cast and extruded samples. However, when printing with a speed of 10 mm/s with UV-curing during printing, a significant increase in strain at failure is achieved. Furthermore, the compressed samples display self-healing abilities at room temperature and almost completely returns to its original state before compression occurred.

Additive manufacturing has provided a pathway for inexpensive and flexible manufacturing of specialized components and one-off parts. At the nanoscale, such techniques are less ubiquitous. Manufacturing at the nanoscale is dominated by lithography tools that are too expensive for small- and medium-sized enterprises (SMEs) to invest in. Additive nanomanufacturing (ANM) empowers smaller facilities to design, create, and manufacture on their own while providing a wider material selection and flexible design. This is especially important as nanomanufacturing thus far is largely constrained to 2-dimensional patterning techniques and being able to manufacture in 3-dimensions could open up new concepts. In this review, we outline the state-of-the-art within ANM technologies such as electrohydrodynamic jet printing, dip-pen lithography, direct laser writing, and several single particle placement methods such as optical tweezers and electrokinetic nanomanipulation. The ANM technologies are compared in terms of deposition speed, resolution, and material selection and finally the future prospects of ANM are discussed. This review is up-to-date until April 2014. Copyright © Materials Research Society 2014.