printing functional materialsnsfam.mae.ufl.edu/slides/lewis.pdf · 2013. 7. 15. · broad range of...
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http://lewisgroup.seas harvard.edu
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Printing Functional Materials Jennifer A. Lewis School of Engineering and Applied Sciences Wyss Institute for Biologically Inspired Engineering
Harvard University
NSF Additive Manufacturing Workshop – 07.11.13
Poly
mer
inks
!
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Broad range of commercial printers and solidification schemes (photocuring, !T, laser sintering, drying, etc.)
Stereolithography 3D Systems
Laser Sintering 3D Systems
Fused Deposition Stratasys
PolyJet Process Objet
Laser Net Shaping Optomec
Electron Beam Melting Arcam
3D Printing Z Corp
Robocasting Robocasting Enterprises
3D Printing – Design, Print, Innovate
Broad range of commercial printers and solidification schemes (photocuring, !T, laser sintering, drying, etc.)
Stereolithography 3D Systems
Laser Sintering 3D Systems
Fused Deposition Stratasys
PolyJet Process Objet
Laser Net Shaping Optomec
Electron Beam Melting Arcam
3D Printing Z Corp
Robocasting Robocasting Enterprises
3D Printing – Design, Print, Innovate
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Several advances needed for 3D printing of high performance, functional materials
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Ø Broaden materials palette for 3DP
Ø Integration of multiple materials
Ø Digitally specify form and function
Ø Improve feature resolution by 100x
Ø Improve throughput by 100x
Our research focus
… expedite transformation from rapid prototyping to manufacturing of functional materials
10x10x5 cm3 ± 50 nm ! ! !1m2x10 cm ± 5 µm! V = 0.1 -10 mm/s ! ! ! !V = 1 -1000 mm/s !!
Moderate Area, High Precision! Large Area, High Speed Stage!
Custom stages designed for 3D printing
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Ink filament printing! ! continuous filament! is extruded through ! deposition nozzle!
Printing ink filaments (in and out of plane)
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Desired Ink Rheology: •" Shear thinning behavior facilitates flow through fine nozzles without clogging
•" Viscoelastic behavior enables printing of self-supporting (spanning) features
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Ink design and deposition
• ink must flow through nozzle without jamming • ink filaments must form high integrity interfaces • ink must solidify rapidly (via gelation, coagulation, or evaporation) • concentrated inks minimize shrinkage during drying
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colloidal inks! sol-gel inks! polyelectrolyte inks!fugitive inks!
nanoparticle inks!
Viscoelastic inks designed for 3D printing
Reactive silver inks for integrated electronics
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Silver particle inks for integrated electronics
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!Silver inks are highly conductive as-printed
Silver particle inks for printed electronics
Solar panels - present design
Rigid, costly, active materials* occupy large area *silicon PV cells and silver interconnects
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100 µm interconnects
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Printing High Aspect Ratio Silver Microelectrodes! 1 µm nozzle 5 µm nozzle 10 µm nozzle
30 µm nozzle 5 µm nozzle
10 µm nozzle
5 µm nozzle 10 µm nozzle 30 µm nozzle
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Flexible photovoltaics
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30 µm nozzle
610 µm nozzle
Sparse array of PV cells; finer interconnects !Sparse array of PV cells; finer interconnects
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10 cmx10 cm
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Printing interconnects and bus bars
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Printed interconnects are highly flexible and can withstand repeated bending (1000’s cycles) without performance loss
Printed interconnects exhibit excellent I-V response
6” polyimide substrate
Flexible concentrator photovoltaics
"ink~1x10-5 #•cm (after 30 min @ 175°C) Sheet resistance = 30 m#/sq
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Conformal printing of electrically small antennas
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VSWR: a measure of signal reflected at component junctions Ideally, VSWR = 1 (no reflected power, no mismatch loss)
Performance characteristics
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Embedded Electronics (carbon ink printed in polymer matrix)
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Embedded Electronics (carbon ink printed in polymer matrix)
Strain Gage Length = 20 mm All printed sequentially in 1mm thick EcoFlex reservoir
with the Wood group
3D Printed of Strain Gage Arrays
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Printed Three-Layer Stretchable Sensors
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For autonomous devices that: 1. Harvest energy
- photovoltaic - thermoelectric - piezoelectric!
2. Store energy
- micro-batteries w/ high energy and power density 3. Perform function
- Mechanical - Sensing - RF
Energy !Harvesting!
Energy !Emission!
Energy !Storage!
Control!
Aim: Print Microbatteries w/ High Power & Energy Density
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Warneke et al., Computer 2001!Lai et al., Adv. Mater. 2010!
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Key Factors Influencing Power & Energy Density
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Printing 3D Interdigitated Microbatteries!
LTO !LFP!
c)
Current collector (Au) !
Glass!
a) Nozzle (30 µm) !
b)
LTO !
Packaging !d)
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Ink Viscosity and Elastic Modulus
LFP ink (cathode)
LTO ink (anode)
Ink rheology tailored for 3D filamentary printing
K. Sun, Lewis, Dillon et al, Adv. Mater. 2013
Printing High Aspect Ratio Structures!
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200 µm 300 µm
Printed 3D Interdigitated Microbattery
K. Sun, Lewis, Dillon et al, Adv. Mater. 2013
Printed and Packaged 3D Microbattery
200 µm
K. Sun, Lewis, Dillon et al, Adv. Mater. 2013
LFP-LTO Full Cell Properties
K. Sun, Lewis, Dillon et al, Adv. Mater. 2013
Microbattery Performance! Z.5!&S9!O/*2+,!:"gv<!!
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High throughput 3D printing
3;!
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5 mm
1 mm
200 μm
All 64 nozzles are 205±3 µm on a side
Multinozzle design based on Murray’s law: Hierarchical branching network Created by CNC milling
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rparent3 = rbranch _ generation
3"
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High throughput printing of 3D architectures Periodic polymer foam
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3D Interpenetrating Architectures!
!" Created model and functional inks with controlled flow behavior
!" Printed flexible electronics, photovoltaics, and sensors from conductive inks
!" Printed 3D Li-ion microbatteries
!" Implemented new multimaterial 3D printing
!" Designed and implemented microvascular nozzle arrays for high throughput printing
Summary
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Thank you!
http://lewisgroup.seas harvard.edu
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