Session: Rising Stars of Mechanical Engineering Celebration & Showcase

Paper Number: 148027

148027 - Career: A Novel Electrically-Assisted Multimaterial Printing Approach for Scalable Additive Manufacturing of Bioinspired Heterogeneous Materials Architectures 

Over millions of years, nature has developed remarkable heterogeneous material architectures in organisms, inspiring the design of high-performance functional materials and structures. Among these, the scaly-foot snail in the depths of the ocean exhibits extraordinary strength and temperature resistance through a unique heterogeneous material architectures captivating accumulation of metallic and polymer layers. The integration of metal and polymer in a multi-material architecture has found widespread applications in fields ranging from 3D electronics, antennas, sensors, and actuators to quantum science and metamaterials. However, the fabrication of patternable metallic structures within intricate 3D polymer objects using conventional microfabrication techniques, such as lithography, deposition, and etching, presents formidable challenges. Existing additive manufacturing (AM)--based hybrid processes for 3D metal-plastic components are beset by high costs, time intensiveness, complexity, and constraints on design flexibility. The presented work supports the innovation of an electrically assisted multi-material AM approach. Successful implementation of this technique will enable the selective construction of metalized layouts in specific regions of a 3D polymer matrix. The creation of multi-material architectures with complex patterns using a singular process in a standard room environment will become possible. Meanwhile, this project will actively involve and mentor students at various educational stages in multimaterial 3D printing. The educational outreach activities will foster diversity and encourage the active participation of minority and underrepresented students in the exciting realm of multimaterial 3D printing. This project aims to elucidate the processing mechanism of an innovative multi-material AM technique. The primary goal is to scale the manufacturing of intricate meta-polymer architectures using a single process by seamlessly integrating programmable electrical fields with photopolymerization. This project seeks to advance the scientific comprehension of the intricate impact of design patterns and parameters of electrical fields on the distribution and morphology of deposited metallic structures on the polymer matrix's surface. In addition, this project aims to deepen scientific understanding by establishing interconnected correlations among interfacial microstructures, surface roughness, printing efficiency, and the mechanical performance of bioinspired meta-polymer architectures. The proposed research will investigate the influences of thermal conduction, diffusion, and printing solution chemistry on the growth of metallic architectures. The acquired insights are poised to contribute significantly to the development of functional metal-polymer architectures applicable across diverse domains such as energy, aerospace, and thermal applications. Anticipated outcomes include a comprehensive understanding of the underlying mechanisms governing the scalable fabrication of complex metallic/polymer structures, providing a valuable foundation for advancements in multimaterial AM.

Presenting Author: Cindy (Xiangjia) Li Arizona State University

Presenting Author Biography: Cindy (Xiangjia) Li is an Assistant Professor in the Department of Aerospace and Mechanical Engineering at Arizona State University's School for Engineering of Matter, Transport, and Energy. Her research is at the forefront of additive manufacturing, with a primary focus on developing innovative multiscale and multi-material processes. She seeks to address current design and manufacturing challenges by drawing inspiration from nature's hierarchical structures and materials. Dr. Li's research work encompasses photopolymerization-based printing techniques, incorporating bioinspired design principles and programmable functional materials. Her research holds promise for a wide range of applications, including interfacial technology, biomedical engineering, soft actuators, optics, and flexible energy devices. She has created several novel approaches for additive manufacturing, enabling the production of complex functional structures and materials that were previously difficult to attain. Dr. Li's contributions to the field are evident in her extensive publication record, featuring numerous articles in prestigious journals and presentations at key conferences. Her recent work has received accolades, including the prestigious Best Paper awards at ASME MSEC2022 and MSEC2023. Furthermore, she has been honored with the 2023 SME Delcie R. Durham Outstanding Young Manufacturing Engineer Award. Notably, Dr. Li’s research outcomes have garnered significant attention from various media outlets, highlighting the impact and relevance of her work. Additionally, her inventive prowess has resulted in the issuance of multiple U.S. patents, further underscoring the novelty and innovation of her manufacturing process developments.

Authors:

Cindy (Xiangjia) Li Arizona State University