A Review on Progress, Challenges, and Prospects of Material Jetting of Copper and Tungsten.

Copper (Cu) and tungsten (W) possess exceptional electrical and thermal conductivity properties, making them suitable candidates for applications such as interconnects and thermal conductivity enhancements. Solution-based additive manufacturing (SBAM) offers unique advantages, including patterning capabilities, cost-effectiveness, and scalability among the various methods for manufacturing Cu and W-based films and structures. In particular, SBAM material jetting techniques, such as inkjet printing (IJP), direct ink writing (DIW), and aerosol jet printing (AJP), present a promising approach for design freedom, low material wastes, and versatility as either stand-alone printers or integrated with powder bed-based metal additive manufacturing (MAM). Thus, this review summarizes recent advancements in solution-processed Cu and W, focusing on IJP, DIW, and AJP techniques. The discussion encompasses general aspects, current status, challenges, and recent research highlights. Furthermore, this paper addresses integrating material jetting techniques with powder bed-based MAM to fabricate functional alloys and multi-material structures. Finally, the factors influencing large-scale fabrication and potential prospects in this area are explored.

A Scalable Solution Route to Porous Networks of Nanostructured Black Tungsten.

This paper studied the feasibility of a new solution-processed method to manufacture black tungsten nanostructures by laser conversion of tungsten hexacarbonyl precursor on the Inconel 625 substrate under argon atmosphere at ambient pressure. The results show that sublimation of the precursor can be prevented if the decomposition temperature (>170 °C) is achieved using the laser heating method. Three different laser powers from 60-400 W were used to investigate the role of laser parameters on the conversion. It was found that lower laser power of 60 W resulted in a mixture of unconverted precursor and converted tungsten. Higher laser powers >200 W resulted in α-W (BCC) in one step without further heat treatment. Different oxygen concentrations from 0.5 ppm to 21 vol% were used in the laser canister to investigate the effect of oxygen concentration on the conversion. It was found that the hard vacuum (>10-4 torr) or hydrogen is not necessary to obtain α-W (BCC). The solar absorptance varied from 63-97%, depending on the amount of precursor deposited on the substrate and oxygen content in the laser canister. This solution-based laser conversion of tungsten precursor is a scalable method to manufacture tungsten coatings for high-temperature applications.

Self-Registration Methods for Increasing Membrane Utilization within Compression-Sealed Microchannel Hemodialysers.

More than 1.2 million people worldwide require regular hemodialysis therapy to treat end stage renal failure. Current hemodialysis systems are too expensive to support at-home hemodialysis where more frequent and longer duration treatment can lead to better patient outcomes. The key cost driver for hemodialysers is the cost of the hemodialysis membrane. Microchannel hemodialysers are smaller providing the potential to use significantly less membrane. Prior work has demonstrated the use of sealing bosses to form compression seals in microchannel hemodialysers. In this paper, estimates show that the percentage of the membrane utilized for mass transfer is highly dependent on the design and registration accuracy of adjacent blood and dialysate laminae. Efforts here focus on the development of a self-registration method to align polycarbonate laminae compatible with compression sealing schemes for membrane separation applications. Self-nesting registration methods were demonstrated with average registration accuracies of 11.4 ± 7.2 µm measured over a 50 mm scale. Analysis shows that the registration accuracy is constrained by tolerances in the embossing process. A dialysis test article was produced using the self-nesting registration method showing a measured average one-dimensional misregistration of 18.5 µm allowing a potential 41.4% of the membrane to be utilized for mass transfer when considering both microchannel and header regions. Mass transfer results provide evidence of a twofold to threefold increase in membrane utilization over other designs in the existing literature.

High-rate synthesis of phosphine-stabilized undecagold nanoclusters using a multilayered micromixer.

Growth in the potential applications of nanomaterials has led to a focus on the development of new manufacturing approaches for these materials. In particular, an increased demand due to the unique properties of nanomaterials requires a substantial yield of high-performance materials and a simultaneous reduction in the environmental impact of these processes. In this paper, a high-rate production of phosphine-stabilized undecagold nanoclusters was achieved using a layer-up strategy which involves the use of microlamination architectures; the patterning and bonding of thin layers of material (laminae) to create a multilayered micromixer in the range of 25-250 µm thick was used to step up the production of phosphine-stabilized undecagold nanoclusters. The continuous production of highly monodispersed phosphine-stabilized undecagold nanoclusters at a rate of about 11.8 (mg s(-1)) was achieved using a microreactor with a size of 1.687 cm(3). This result is about 500 times over conventional batch syntheses based on the production rate per reactor volume.

Organic solvent nanofiltration for microfluidic purification of poly(amidoamine) dendrimers.

A nanofiltration method has been developed in a microfluidic format for the continuous-flow pressure-driven purification of half-generation poly(amidoamine) (PAMAM) dendrimers, a family of macromolecules characterized by highly branching structures radiating from a central core, without additional solvents or buffers. An organic solvent resistant nanofiltration membrane, STARMEM 122, has been fully integrated into a hard polymer microfluidic module by transmission laser welding. The membrane was initially characterized in a bench-top test fixture to determine the solvent permeance and percent rejection of a surrogate molecule, Rhodamine B, at lower than typical operating pressures (P<7 bar). The microfluidic module then underwent similar testing at 1.4 bar with the surrogate and with the generation-0.5 PAMAM dendrimer. This approach to nanofiltration will readily interface to upstream microreactors.