One limitation of run-of-the-mill 3D printers is that the structure must essentially be built as a series of layers, each one supporting the next.
There’s no fancy name for the technology yet (unless laser-assisted direct ink writing counts), but the gist of it is this: A nozzle moves along a preset path sending out a thin stream of silver nanoparticles, while at the same time a laser follows its progress, heating the particles and solidifying them into a freestanding filament thinner than a human hair.
The results are beautiful and flexible single-piece structures that can take almost any form
Inside the nozzle, the flow of nanoparticles has to be precisely controlled to keep the metal thread’s width uniform, and the laser must adjust as well so as not to leave any particles un-annealed, or apply too much heat and solidify the ink inside the extruder.
The results are beautiful and flexible single-piece structures that can take almost any form — useful for creating structural elements like tiny springs and buttresses, as well as circuits.
“I am truly excited by this latest advance from our lab, which allows one to 3D print and anneal flexible metal electrodes and complex architectures ‘on-the-fly,’” said lead researcher Jennifer Lewis in a news release. “This sophisticated use of laser technology to enhance 3D printing capabilities not only inspires new kinds of products, it moves the frontier of solid free-form fabrication into an exciting new realm.”
The technique is demonstrated in the form of some pretty 3D wire butterflies, but you can imagine it being used to build custom structures for a variety of purposes — wiring on custom medical devices or rapid prototypes, for instance.
Lewis’s research was published today in the Proceedings of the National Academy of Sciences.
The 3D printing industry has had a rough go of it, of late. In a few short years, it’s gone from technology darling to victim of its own industry hype, a move that has had serious implications for some of the industry’s biggest players.
But as the consumer-facing wing of the space has seemingly hit the skids, another aspect of the technology is gaining serious momentum. Late last month, industry giant Stratasys announced a pair of new technologies and manufacturing partnerships with Boeing and Ford. Three months prior, HP showed off a pair of washing machine-sized devices aimed at taking on more established industrial 3D printing companies.