innorobo 2016 i3dp - 3d printing with novel materials production, processing & performance
TRANSCRIPT
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3D Printing with Novel MaterialsProduction, Processing & Performance
Michael Petch – Black Dog ConsultingInside 3D Printing Conference, Paris. 26th May 2016
[email protected]@michaellpetch
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10 CERAMICS:FUTURE?
11 GRAPHENE:WHAT?
03 ABOUT ME
04 MATERIAL DISCOVERY.
05 LONG TERM STRATEGY
06 CERAMICS:WHAT?
07 CERAMICS:MATERIALS
14 GRAPHENE:PROCESSING
15 GRAPHENE:PERFORMANCE
16 GRAPHENE:FUTURE?
17 OTHER MATERIALS
agenda 3D PRINTING & NOVEL MATERIALS
08 CERAMICS:PROCESSING
09 CERAMICS:PERFORMANCE
12/13 GRAPHITE/GRAPHENE:PRODUCTION
18 QUESTIONS
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3MICHAEL PETCHAuthor, analyst, & consultant.
Image Credit: Gyges 3D
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4Material Discovery & Development
1886Aluminium $1,200 / kg
2016Aluminium
$2 / kg.
2015US 100% reliant on
imports for 19 critical minerals
Image Credits: AP Photo, UT Library, Compound Chem, US Geological Survey.
Smartphones contain half elements in
periodic table.
Av. Life = 3 years
(Bakker, 2014)
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“Over the long term, actions to increase resiliency may include the development of new methods of extraction, processing, and manufacturing that promote the efficient use of materials; increased recovery of materials from waste and scrap; and research and development of alternative materials and new product designs to reducethe demand for limited materials.”Testimony to Senate Energy and Natural Resources Committee on May 12, 2015 by Richard Silberglitt, RAND
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6Ceramics: What?
Image Credits: Petr Novak Wikipedia , Engineering Civil, Empa
50% of everything made this year will be made from ceramics (Purnell, 2013)
Post-hard machining incurs up to 80% of the overall manufacturing costs of a ceramic product (Travitzky et al., 2014)
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Ceramics: MaterialsCeramics vs Fine / Advanced Ceramics
Chart Data Source: Fine Ceramics World
Ceramic pasteCeramic powderLiquid binder (for binder jet)Photo-curing ceramic composite resinPreceramic paper
Materials for AM
SiC preceramic paper for LOM
(Travizky, 2014)
UV curable monomers & UV photo initiator.
(Schaedler et al., 2016)
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8Ceramics: Processing
Image Credits: Laurens van Lieshout, Sandia National Laboratories/Randy Montoya, Heraclitus by Hendrick ter Brugghen, HRL Laboratories LLC, Schaedler et al., 2016.
AM techniques for working with ceramics.
1 Foil supply. 2 Heated roller. 3 Laser beam. 4. Scanning prism. 5 Laser unit. 6 Layers. 7 Moving platform. 8 Waste.
Laminated Object Manufacturing with
preceramic paperRobocasting with
hydrogels & ceramic slurries
UV Stereolithography with silicon oxycarbide
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9Ceramics: Performance
Image Credits: Özkol et al., 2012, Feilden et al., 2016, Schaedler et al., 2016, HRL Laboratories/Dan Little, General Electric GE9X , Joannopoulos et al., 2011.
Biomedical, aerospace, electronics & semiconductors. Complex geometry, low porosity, high strength & thermal resistance.
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10Ceramics: Future?
Image Credits: NASA, Carpenter, J.
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11Graphene: What?
Image Credits: Nobel Museum, Alexander AIUS, Tian et al. 2006, Novoselov & Geim: Roadmap for Graphene 2015.
A two-dimensional, atomic scale, monolayer, polyaromatic hydrocarbon. A single sheet of graphite.
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Graphite: ProductionGraphite demand to increase by 200% within 4 years.*
Image Credit: USGS, 2016, *Benchmark Mineral Intelligence
China: 72% installed capacity worldwide, 55% total flake graphite production.
3 ton natural flake graphite
=1 ton spheroidal
graphite
800 million tons =
World recoverable graphite
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Graphene: ProductionGraphite must be intercalated to render it susceptible to exfoliation.
Image Credit: Garg et al., 2014, Ben Mills
Sulfuric acid
Potassium permangate
Sodium nitrate
Potassium persulfate
Phosphorus pentoxide
1. Oxidation of graphiteBrodie Method (1859)Hummers Method (1958)Modified Hummers (Kovtyukhova, 1999 & Tour, 2010)
2. Exfoliation 3. Reduction 4. Dispersal or Nanocomposite
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14Graphene: Processing
Image Credits: Griffiths, 2015, Dul et al. 2016, Jabari & Toyserkani, 2015.
AM & fabrication techniques for working with graphene.
“Gbot” UV curable 3D printable graphene ink
Extrusion with thermoplastic polymer nanocomposite (PNG)
Aerosol jet printing for graphene interconnects
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15Graphene: Performance
Image Credits: Zhu et al., 2015, Zhu et al., 2016, Hersam et al., 2015
Super capacitors, electronic & biomedical applications
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16Graphene: Future?
Image Credits: Nokia, Volvo, Columbia University, Pacific Water
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17Other Materials & Applications
Image Credits: Molybdenum, John Rogers, Wuhan National Laboratory for Optoelectronics, Drexler & Pamlin, 2013
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ReferencesAshby, M. F. (2005). Materials selection in mechanical design. MRS Bull,30(12), 995. Ashby, M. F. (2012). Materials and the environment: eco-informed material choice. Elsevier. Bach, C., & Eggenschwiler, P. D. (2011). Ceramic foam catalyst substrates for diesel oxidation catalysts: Pollutant conversion and operational issues(No. 2011-24-0179). SAE Technical Paper. Benchmark Mineral Intelligence. (2016, March 23). Chart: Flake graphite capacity utilisation drops below 50% | Benchmark Minerals. Retrieved from http://benchmarkminerals.com/Blog/chart-flake-graphite-capacity-utilisation-drops-below-50/ Brodie Method of Oxidizing Graphite (1859) in Staudenmaier, L. (1898). Verfahren zur darstellung der graphitsäure. Berichte der deutschen chemischen Gesellschaft, 31(2), 1481-1487. Brown, T. J., Idoine, N., Raycraft, E. R., Shaw, R. A., Deady, E. A., Rippingale, J., ... & Rodley, J. (2014). World mineral production 2008-12. British Geological Survey. Bakker, C., den Hollander, M., van Hinte, E., & Zijlstra, Y. (2014). Products that Last: Product Design for Circular Business Models. TU Delft Library.
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ReferencesBall, P. (1999). Made to measure: New materials for the 21st century. Princeton University Press. Crowley, C., Birchall, M., & Seifalian, A. M. (2015). Trachea transplantation: from laboratory to patient. Journal of tissue engineering and regenerative medicine, 9(4), 357-367. Deckers, J., Vleugels, J., & Kruth, J. P. (2014). Additive manufacturing of ceramics: A review. J. Ceram. Sci. Technol, 5(4), 245-260. Drexler, K. E. (2013). Radical abundance: How a revolution in nanotechnology will change civilization. PublicAffairs. Dul, S., Fambri, L., & Pegoretti, A. (2016). Fused deposition modelling with ABS–graphene nanocomposites. Composites Part A: Applied Science and Manufacturing, 85, 181-191. Eckel, Z. C., Zhou, C., Martin, J. H., Jacobsen, A. J., Carter, W. B., & Schaedler, T. A. (2016). Additive manufacturing of polymer-derived ceramics.Science, 351(6268), 58-62. Feilden, E., Blanca, E. G. T., Giuliani, F., Saiz, E., & Vandeperre, L. (2016). Robocasting of structural ceramic parts with hydrogel inks. Journal of the European Ceramic Society, 36(10), 2525-2533.
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ReferencesGalvez, M. E., Martinez, I., Beyssac, O., Benzerara, K., Agrinier, P., & Assayag, N. (2013). Metasomatism and graphite formation at a lithological interface in Malaspina (Alpine Corsica, France). Contributions to Mineralogy and Petrology, 166(6), 1687-1708. Garg, B., Bisht, T., & Ling, Y. C. (2014). Graphene-based nanomaterials as heterogeneous acid catalysts: a comprehensive perspective. Molecules,19(9), 14582-14614. Griffiths, L. (2015, October 9). 3D Printing With Graphene - A Material for the 21st Century - TCT Magazine. Retrieved May 10, 2016, from http://www.tctmagazine.com/3D-printing-news/3d-printing-with-graphene-a-material-for-the-21st-century/ Hench, L. L. (2006). The story of Bioglass®. Journal of Materials Science: Materials in Medicine, 17(11), 967-978. Hummers Jr, W. S., & Offeman, R. E. (1958). Preparation of graphitic oxide.Journal of the American Chemical Society, 80(6), 1339-1339. Jabari, E. , & Toyserkani, E. (2015). Micro-scale aerosol-jet printing of graphene interconnects. Carbon, 91, 321-329.
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ReferencesJoannopoulos, J. D., Johnson, S. G., Winn, J. N., & Meade, R. D. (2011).Photonic crystals: molding the flow of light. Princeton university press. Kirihara, S. (2015). Stereolithography of ceramic components: fabrication of photonic crystals with diamond structures for terahertz wave modulation.Journal of the Ceramic Society of Japan, 123(1441), 816-822. Kovtyukhova, N. I., Ollivier, P. J., Martin, B. R., Mallouk, T. E., Chizhik, S. A., Buzaneva, E. V., & Gorchinskiy, A. D. (1999). Layer-by-layer assembly of ultrathin composite films from micron-sized graphite oxide sheets and polycations. Chemistry of Materials, 11(3), 771-778. Macfarlane, A., & Martin, G. (2011). The glass bathyscaphe: how glass changed the world. Profile Books. “Materials Genome Initiative Strategic Plan” ( National Science and Technology Council, Washington, DC, 2014 ), available at http://acceleratornetwork.org/wp-uploads/2015/01/mgi_strategic_plan_-_dec_2014.pdf (accessed May 2016) Novoselov, K. S., Geim, A. K., Morozov, S. V., Jiang, D., Zhang, Y., Dubonos, S. A., ... & Firsov, A. A. (2004). Electric field effect in atomically thin carbon films. science, 306(5696), 666-669. Novoselov, K. S., Geim, A. K., Ferrari, A. C., Bonaccorso, F., Fal'Ko, V., Roche, S., Bøggild, P., ... & Garrido, J. A. (2015). Science and technology roadmap for graphene, related two-dimensional crystals, and hybrid systems. Nanoscale,7(11), 4598-4810
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ReferencesÖzkol, E., Zhang, W., Ebert, J., & Telle, R. (2012). Potentials of the “Direct inkjet printing” method for manufacturing 3Y-TZP based dental restorations.Journal of the European Ceramic Society, 32(10), 2193-2201. Pezzotti, G., Bock, R. M., McEntire, B. J., Jones, E., Boffelli, M., Zhu, W., ... & Yamamoto, T. (2016). Silicon Nitride Bioceramics Induce Chemically Driven Lysis in Porphyromonas gingivalis. Langmuir, 32(12), 3024-3035. Purnell, P. (2013). The carbon footprint of reinforced concrete. Advances in Cement Research, 25(6), 362-368. Robocasting: New Way To Fabricate Ceramics". Sandia.gov. N.p., 2016. Web. 10 May 2016. Robocasting.net. “About” N.p., 2016. Web. 10 May 2016. Royal Swedish Academy of Sciences. (2010, October 5). The 2010 Nobel Prize in Physics - Press Release. Retrieved from http://www.nobelprize.org/nobel_prizes/physics/laureates/2010/press.html Saha, A., Raj, R., & Williamson, D. L. (2006). A Model for the Nanodomains in Polymer‐Derived SiCO. Journal of the American Ceramic Society, 89(7), 2188-2195.
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ReferencesSchleunitz, A., Klein, J. J., Houbertz, R., Vogler, M., & Gruetzner, G. (2015, April). Towards high-precision manufacturing of 3D optical components using UV-curable hybrid polymers. In SPIE OPTO (pp. 93680E-93680E). International Society for Optics and Photonics. Teobaldi, G., Ohnishi, H., Tanimura, K., & Shluger, A. L. (2010). The effect of van der Waals interactions on the properties of intrinsic defects in graphite.Carbon, 48(14), 4145-4161. Tian, Y., Pesika, N., Zeng, H., Rosenberg, K., Zhao, B., McGuiggan, P., ... & Israelachvili, J. (2006). Adhesion and friction in gecko toe attachment and detachment. Proceedings of the National Academy of Sciences, 103(51), 19320-19325. Marcano, D. C., Kosynkin, D. V., Berlin, J. M., Sinitskii, A., Sun, Z., Slesarev, A., ... & Tour, J. M. (2010). Improved synthesis of graphene oxide. ACS nano,4(8), 4806-4814. Travitzky, N., Bonet, A., Dermeik, B., Fey, T., Filbert‐Demut, I., Schlier, L., ... & Greil, P. (2014). Additive Manufacturing of Ceramic‐Based Materials.Advanced Engineering Materials, 16(6), 729-754. U.S. Geological Survey, 2016, Mineral commodity summaries 2016: U.S. Geological Survey, 202 p., http://dx.doi.org/10.3133/70140094.
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