Large Scale Vat-Photopolymerization of Investment Casting Master Patterns: The Total Solution.

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.

Hot Lithography Vat Photopolymerisation 3D Printing: Vat Temperature vs. Mixture Design.

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.

3D conformal bandpass millimeter-wave frequency selective surface with improved fields of view.

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.

3D-printable zwitterionic nano-composite hydrogel system for biomedical applications.

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.

Layer-dependent properties of material extruded biodegradable Polylactic Acid.

Polylactic acid (PLA) is a biodegradable, biocompatible and non-toxic biopolymer with good mechanical properties, and is commonly used for the additive manufacture of PLA-based biomedical devices. Such devices are available in a range of sizes and thicknesses, with smaller devices capable of being realised via additive manufacturing in just a few layers. Due to their thermal history and thermal degradation, the thermal, molecular weight and mechanical properties of each layer was different when the raw material was melted, and the in-course layer was deposited to the previous layer. This study investigated the effect of the number of layers on mechanical, thermal and molecular weight properties, and the relationship between them. Material extruded ISO 527-2 type 5A specimens with 1-, 2-, 3-, 4-, 5-, 7- and 10-layers were prepared with the cutting die. Results indicated that the degree of crystallinity was found to decrease from 8% to 0.5% with an increasing number of layers. This was likely due to different cooling rates, where the molecular weight was lowest for 1-layer and increased with the increasing number of layers until it almost reached that of the bulk material. Additionally, ultimate tensile strength and strain increased with an increasing number of layers, while Young's Modulus decreased due to heterogeneous material structure. Of all obtained results, there was no significant difference between 5- and 10-layer in terms of mechanical and thermal properties.

High throughput nanofabrication of silicon nanowire and carbon nanotube tips on AFM probes by stencil-deposited catalysts.

A new and versatile technique for the wafer scale nanofabrication of silicon nanowire (SiNW) and multiwalled carbon nanotube (MWNT) tips on atomic force microscope (AFM) probes is presented. Catalyst material for the SiNW and MWNT growth was deposited on prefabricated AFM probes using aligned wafer scale nanostencil lithography. Individual vertical SiNWs were grown epitaxially by a catalytic vapor-liquid-solid (VLS) process and MWNTs were grown by a plasma-enhanced chemical vapor (PECVD) process on the AFM probes. The AFM probes were tested for imaging micrometers-deep trenches, where they demonstrated a significantly better performance than commercial high aspect ratio tips. Our method demonstrates a reliable and cost-efficient route toward wafer scale manufacturing of SiNW and MWNT AFM probes.