TY - JOUR
T1 - Vat photopolymerization of fly-like, complex micro-architectures with dissolvable supports
AU - Xu, Zhenpeng
AU - Hensleigh, Ryan
AU - Gerard, Nikhil JRK
AU - Cui, Huachen
AU - Oudich, Mourad
AU - Chen, Wentao
AU - Jing, Yun
AU - Zheng, Xiaoyu (Rayne)
N1 - Funding Information:
The authors would like to thank the US National Science Foundation CAREER award ( 2048200 ), US Air Force Office of Scientific Research ( FA9550-18-1-0299 ), US Office of Naval Research ( N00014-18-1-2553 and N00014-19-1-2723 ), US Defense Advanced Research Projects Agency ( D20AP00001-02 ), and the US National Science Foundation ( 2001677 ) for their financial support. Y. J. would like to thank startup support from Pennsylvania State University, USA.
Publisher Copyright:
© 2021
PY - 2021/11
Y1 - 2021/11
N2 - Recent advances in additive manufacturing of complex geometries enabled the creation of mechanical metamaterials whose exotic properties are based on local control of complex cell geometries. Overhanging and free-hanging features that lack continuous support layers in the previous build volume cannot be directly manufactured, imposing a major design limitation. The resulting metamaterials are limited to single homogenous structural materials, and inherently self-supporting geometries, resulting in constraints of achievable architectures. Realizing arbitrary features is compelling but is inherently limited by process and material support constraints. Here we present a novel light-based additive manufacturing approach capable of printing arbitrary micro-architectures comprising a large array of internally suspended features, large span overhang, and high aspect ratio struts. This method eliminates the need for manual removal of internal supports and enables a suite of multi-functional metamaterials with a range of designed properties, including wide bandgaps for elastic waves at low frequency, switchable wave transmissions, and products requiring no post support removal. We describe the synthesis and rapid printing of a variety of metamaterials comprising an extensive array of suspended features and demonstrate their metamaterial behaviors. The proposed approach removes scale and unit cell limitations and is capable of achieving embedded features across multiple materials.
AB - Recent advances in additive manufacturing of complex geometries enabled the creation of mechanical metamaterials whose exotic properties are based on local control of complex cell geometries. Overhanging and free-hanging features that lack continuous support layers in the previous build volume cannot be directly manufactured, imposing a major design limitation. The resulting metamaterials are limited to single homogenous structural materials, and inherently self-supporting geometries, resulting in constraints of achievable architectures. Realizing arbitrary features is compelling but is inherently limited by process and material support constraints. Here we present a novel light-based additive manufacturing approach capable of printing arbitrary micro-architectures comprising a large array of internally suspended features, large span overhang, and high aspect ratio struts. This method eliminates the need for manual removal of internal supports and enables a suite of multi-functional metamaterials with a range of designed properties, including wide bandgaps for elastic waves at low frequency, switchable wave transmissions, and products requiring no post support removal. We describe the synthesis and rapid printing of a variety of metamaterials comprising an extensive array of suspended features and demonstrate their metamaterial behaviors. The proposed approach removes scale and unit cell limitations and is capable of achieving embedded features across multiple materials.
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U2 - 10.1016/j.addma.2021.102321
DO - 10.1016/j.addma.2021.102321
M3 - Article
AN - SCOPUS:85115982713
VL - 47
JO - Additive Manufacturing
JF - Additive Manufacturing
SN - 2214-8604
M1 - 102321
ER -