IDML Introduction

Functional Micro/Macro Additive Manufacturing
Jae-Won Choi, Ph.D., Assistant Professor

Director, Innovative Design and Manufacturing Laboratory, Mechanical Engineering, The University of Akron
Feel free to contact if you have any questions E-mail: palagent@gmail.com
J.W. Choi J.W. Choi
Contents
Introduction Projects Review Applications - 3D Functional Microstructures Future Work
Innovative Design and Manufacturing Lab
J.W. Choi J.W. Choi
Introduction Additive Manufacturing Additi M f t i
J.W. Choi J.W. Choi
Additive Manufacturing (AM)

What is AM ?
Process of joining materials to make objects from 3D model data, as opposed to subtractive manufacturing (lathes, mills, etc.) Definition AM is a standard terminology defined by ASTM gy y Rapid Prototyping (RP), Solid Freeform Fabrication (SFF), Layered M L d Manufacturing (LM) Addi i F b i i f i (LM), Additive Fabrication, etc. Synonyms
Pre-production (Rapid Prototyping) to Rapid Manufacturing and Tooling. Coverage
J.W. Choi J.W. Choi
Representative AM Process
Stereolithography Apparatus (SLA)
Working principle
Curing photocrosslinkable liquid material using a laser
Examples
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Fused Deposition Modeling (FDM)
Working Principle
Depositing a molten material using a filament and heated nozzles
Examples
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Selective Laser Sintering (SLS)
Working Principle
Sintering a powder material using a CO2 laser
Examples
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Electron Beam Melting (EBM)
Working Principle
selectively melting Ti6Al-4V powder using an electron beam
Examples
J.W. Choi J.W. Choi
Additive Manufacturing
Various processes
Additive manufacturing processes
Powder materials
Liquid materials
Solid materials
Sintering g process
Printing or joining process
Extrusion p process (molten material) Fused Deposition Modeling (FDM) Solid Ground Curing (SGC) Photomasking p processes
Liquid polymerizati on process
Bonding of sheets with adhesive Laminated Object Manufacturing (LOM)
Bonding of sheets with light
Selective Laser Sintering (SLS)
3D Printing (3DP)
Laser processes
Deposition process
Foil polymerizati on
Dynamicmask Projection
Stereolithogr aphy (SL)
Multi-Jet Modeling (MJM)
J.W. Choi J.W. Choi
Projects Review - Macro Additive

Manufacturing
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Micro channel Micro-channel Fabrication in SLA Using micro-wires in SLA
Build open micro-channel
Place micro-wire in channel
Complete build (embed wire)
Remove wire
31.6 m wire
57.2 57 2 m wire i
83.5 83 5 m wire
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Choi, J.W. *, Quintana, R., Wicker, R., Rapid Prototyping Journal, 17 (5), 2011.
J.W. Choi J.W. Choi
Advanced AM I
Multiple Material Stereolithography (MMSL)
Build using material 1 Raise the platform
Rotate material vat 1 under build platform
Finished multiple material part
Manual Cleaning and drying the platform with a part
Continue the process to build multiple material functional devices Build using material 2
Rotate material vat 2 under build platform
Kim, H.C., Choi, J.W., Wicker, R.B., Rapid Prototyping Journal, 16: 232-240, 2010. Kim, H.C., Choi, J.W., MacDonald, E., Wicker, R.B. International Journal of Advanced Manufacturing Technology, 46: 1161-1170, 2010. Innovative Design and Manufacturing Lab 12
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Advanced AM I
Choi, J.W., Kim, H.C., Wicker, R., Multi-material stereolithography, Journal of Materials Processing Technology, 211: 318-328, 2011.. Innovative Design and Manufacturing Lab 13
J.W. Choi J.W. Choi
Advanced AM I
1 2
Building the bottom using the material 1 (diluted ProtoTherm 12120 (Red))
Building the half hollow structure using the g g material 2 (diluted WaterShed 11120 (Clear))
Building the other half hollow structure using the material 3 (diluted 14120 White)
Building the staircase, spirals, and top using the material 1
Applications (NGCs, medical models) 14
J.W. Choi J.W. Choi
Advanced AM II
Flexible Fused Deposition Modeling (FFDM)
Choi, J.W., Medina, F., Kim, C., Espalin, D., Rodriguez, D., Stucker, B., Wicker, R. Development of a Mobile Fused Deposition Modeling System with Enhanced Manufacturing Flexibility, Journal of Materials Processing Technology, 211: 424-432, 2011 Innovative Design and Manufacturing Lab 15
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Advanced AM II
Flexible Fused Deposition Modeling (FFDM)
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Projects Review
Micro Additive Manufacturing
:Microstereolithography
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Micro AM - Microstereolithography
What is Microstereolithography (SL)
Process of layer-by-layer joining materials to make microobjects Evolved from conventional stereolithography (SL) Typically the x-y resolution of a few microns and z resolution of a few tens of microns Types
Scanning SL
Si il t conventional SL Similar to ti l Using a focused laser (beam spot size 10 m)
Projection SL
Using a physical or dynamic (or digital) mask (pattern size 5 m)
Innovative Design and Manufacturing Lab 18
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SL - History
IC Technology
1960 1970
MEMS
1980
LIGA, Berker et al. SLA, Hull Ikuta and Kirowatari Tagaki et al. Two-photon, Maruo et al. Mask-based MSL,Nagomoto et al. LCD MSL B h l LCD-MSL, Bertsch et al.
1986 1988 1993 1990
1996
199 1997 2000

MSL : Microstereolithography LCD : Liquid crystal display DMD : Digital micromirror device
DMD-MSL, Bertsch et al. g, Commercial Microsintering, Micromac Acculas, Commercial MSL, D-Mac
2001
2003 2004
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DMD-based projection SL
Choi, J W Ha, Y M Lee S H Choi K H Choi J.W., Ha Y.M., Lee, S.H., Choi, K.H., Journal of Mechanical Science and Technology 20: 2094 2104 2006 Technology, 2094-2104, 2006. Choi, J.W., Wicker, R.B., Cho, S.H., Ha, C.S., Lee, S.H., Rapid Prototyping Journal, 15: 59-70, 2009. Innovative Design and Manufacturing Lab 20
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Configuration
Light emission subsystem
Mercury lamp with the output of 200 W Filtered at the wavelength of 365 nm
EXFO OmniCure S2000TM model

Lamp output
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Configuration
Dynamic pattern generation subsystem
Texas Instrument 1024 by 768 micro-mirror array Mirror size of 13.68 m 12 tilting angle to selectively reflect a light bundle
-12 degrees tilt (off t t ) ( ff state) Flat state
DMD
Off state (dummy light) (-12 degrees tilt)
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Flat state (not energized)
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+12 degrees tilt (on state)
On state for image-forming (+12 degrees tilt) Incident light
DMD Discovery 1100TMController Board
DMD operation
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Configuration
Image focusing subsystem
Objective lenses with different numerical apertures (N.A.)
NA: 0.13 NA: 0.3 NA: 0.45
Build subsystem
High-resolution z stage (100 nm) ) Custom made platform
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Deep-dip process
Settling time is required Low viscosity resin is required
Projection lens Fabricated layer Focused light Unstable resin surface Platform Vat Refreshed resin surface
(a)
Resin
(b)
(c)
(d)
(a) Step 1 : Irradiation for given time (b) Step 2 : Fast moving downward to cover fabricated layer (c) Step 3 : Slow moving upward to desired position (d) Step 4 : Waiting until resin surface becomes flat
J.W. Choi J.W. Choi
Material issues
Photocrosslinkable and low viscosity liquid materials Commercial resins
SI40 provided b 3D S t id d by Systems (R k Hill SC) (Rock Hills, WaterShed 11120, ProtoTherm 12120, and Somos 14120 White provided by DSM Somos (New Castle, DE)
Most of commercial resins are too viscous

acrylate- or diacrylate-based monomers as diluents A viscosity of less than ~200 cP is recommended 200 propoxylated (2) neopentyl glycol diacrylate 1,6-hexanediol diacrylate (HDDA) i b isobornyl acrylate (IBXA or IBOA) l l t
J.W. Choi J.W. Choi
Material issues
Monomers, oligomers, and polymers available
Crosslinkable sites such as a carbon double bond Photoinitiator (PI) is required
Depends on the wavelength of a chosen light
Overcure and cure depth control

Curing characterization for photocrosslinkable materials is defined by critical energy (Ec) and light penetration depth (Dp) For cure depth control, a light absorber is required
J.W. Choi J.W. Choi
Fabrication examples
Dime
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Fabrication examples
~30 m 30 ~30 m ~50 m
~10 m 10 ~130 m
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Advanced SL I
Large-area fabrication
Collimating lens set DMD Optical fiber Reflecting mirror Focusing unit Lamp
Additional high precision x-y stage i i t under the system LightGate
Tube lens Z Stage
X-Y Stage
Resin Vat Objective lens
Ha, Y.M., Choi, J.W., Lee, S.H., Journal of Mechanical Science and Technology, 22: 514~521, 2008. Innovative Design and Manufacturing Lab 29
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Advanced SL I
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Advanced SL I
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Advanced SL I
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Advanced SL I
3D model
fabricated teeth
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Advanced SL II
Multi-material fabrication
Using additional syringe pump and custom-made small vat Manual washing process
Choi, J.W. *, MacDonald, E., Wicker, R.B., International Journal of Advanced Manufacturing Technology, 49: 543-551, 2010. Innovative Design and Manufacturing Lab 34
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Advanced SL II
Single material fabrication in the developed system
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Advanced SL II
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SL Applications - 3D Functional
Microstructures
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SL Applications I
Fluidics Biomedical Fluidics,

sleeve
3D micro-vanes within a sleeve in cataract surgery

Phacoemulsification
Removing the crystalline ultrasound irrigation
maintaining a constant pressure dissipating heat maintaining an endothelial cell survival Impinging flow from the irrigation solution on the corneal endothelial cells in the inner eye damages these cells during the procedure
Irrigation tip
phacoemulsifier
artificial lens
It is required t reduce the fl i i d to d th flow velocity during the procedure

Source: http://www.eyesurgeryeducation.com
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J.W. Choi J.W. Choi
SL Applications I
Fluidics Biomedical Fluidics,
3D micro-vanes within a sleeve in cataract surgery
Choi, J.W. *, Yamashita, M., Sakakibara, J., Kaji, Y., Oshika, T., Wicker, R. Biomedical Microdevices, 12: 875-886, 2010. Innovative Design and Manufacturing Lab 39
J.W. Choi J.W. Choi
SL Applications II
Electrical Mechanical Electrical,
3D micro-patterns for conductive wires
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SL Applications III
Tissue engineering scaffolds
Tissue Engineering
Artificial structure or template to support implanted or seeded cells to be a three-dimensional tissue

scaffolds requirements: degradation rate, porosity, pore size, shape, distribution, and mechanical properties di t ib ti d h i l ti materials requirements
Biodegradability: degradable into nontoxic products, leaving the desired living tissue Biocompatibility: not to provoke any unwanted tissue response to the implants and to possess the right surface chemistry to promote cell attachment & function M Manufacturability f t bilit
optimal scaffold pore size and geometry vary according to cell types
3D design and fabrication are necessarily needed
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J.W. Choi J.W. Choi
SL Applications III
Tissue Engineering
Tissue engineering scaffolds

Biodegradable/biocompatible/photocrosslinkable Poly(propylene fumarate) (PPF) is a good material
O i i ll d Originally developed f b l d for bone regeneration ti Synthesized using propylene glycol and diethyl fumarate PPF can be diluted with diethyl fumarate
O EtO O
Diethyl fumarate (DEF) Propylene glycol (PG)
OEt
HO
OH
HO
O O
PPF
O
n
OH
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J.W. Choi J.W. Choi
SL Applications III
Tissue Engineering
Tissue engineering scaffolds using PPF/DEF
Choi, J.W., Choi, K.H., Chung, I., Ha, C.S., Lee, S.H, Wicker, R.B., Journal of Materials Processing Technology, 29: 5494-5503, 2009 Innovative Design and Manufacturing Lab 43
J.W. Choi J.W. Choi
SL Applications IV
Microneedles for transdermal drug delivery
Stratum corneum is the main barrier to delivery drugs To avoid the barrier, painless microneedles can puncture the skin with micron size holes micron-size Microneedles can potentially include drugs
stratum corneum capillary network papillary layer blood circulation permeation uptake DRUG Epidermis Dermis Subdermal tissue DRUG permeation Epidermis Dermis
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stratum corneum microneedle
stratum corneum punctured holes
uptake
Epidermis Puncture process
J.W. Choi J.W. Choi
SL Applications IV
Microneedles for transdermal drug delivery
~460 60 m ~160 m
Choi, J.W., Irwin, M., Wicker, R.B., Proc. of SPIE, Photonics West, Jan. 23-28 2010, San Francisco, CA, 7596: 75960H-1~11. Innovative Design and Manufacturing Lab 45
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SL Applications V
Microlens arrays for optics
collimating light in an optoelectronic sensor, an optical communication device, and confocal microscopes
Park, I.B., Lee, S.D., Kwon, T.W., Choi, J.W., Lee, S.H. Journal of the Korean Society for Precision Engineering, 25: 123-130, 2008. Innovative Design and Manufacturing Lab 46
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SL Applications VI
Nerve guidance conduits (NGCs)
To support peripheral nerve regeneration Using poly(ethylene glycol) (PEG) with the molecular weight of 3400 (non toxic) (non-toxic)
Choi, J.W., Irwin, M., Wicker, R.B., Proc. of SPIE, Photonics West, Jan. 23-28 2010, San Francisco, CA, 7596: 75960H-1~11. Innovative Design and Manufacturing Lab 47
J.W. Choi J.W. Choi
Current Work
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Current Work I
TITLE: Multi-scale, multi-material additive manufacturing and its application
Collimating lens Optical fiber DMD board Prism Tube lens Focusing unit Lamp
Continuous projection for multimulti scale fabrication Automatic material changeover Automatic washing g mechanism
Cleaning system X-Y stage Z stage Small vat Reflecting mirror Objective lens
Pump system p y
Vat for used material
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Current Work II
TITLE: Low-Temperature, Low-Cost Direct Writing of Photocrosslinkable Solutions Filled with Copper Nanoparticles for 3D Conductive Patterns on Flexible Substrates
Using geometry-controlled nanoparticles
Copper nanoparticles in photocrosslinkable solution
Microstereolithography process with material changeover
Final 3D conductive patterns on a flexible substrate
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J.W. Choi J.W. Choi
Current Work III

TITLE: Multi-Material, Large-Area Microstereolithography of Biodegradable/Biocompatible 3D Microneedle Arrays for Long-Term, Sustained, and Controlled Drug Release
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Current Work IV
TITLE: Direct Writing with Micro/Macro Stereolithography for 3D Electronics
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Collaborators
Dr. Ryan Wicker, UTEP AM, DW Dr. Eric MacDonald, UTEP 3D electronics Dr. Namsoo Kim, UTEP Nanoparticle synthesis, Packing technology Dr. Karina Arcaute, UTEP Nerve Guidance Conduits Dr. Kenneth Church, UTEP, nScript Micro-dispensing Micro dispensing Dr. Michael Irwin, UTEP Chemistry, Biomaterials Dr. Brenda Mann, Univ. of Utah Poly (ethylene glycol) synthesis Dr. Dr Brent Stucker Univ of Louisville Ultrasonic Consolidation (UC),Flexible FDM Stucker, Univ. (UC) Flexible Dr. Jun Sakakibara, Tsukuba Univ., Japan - Fluidics Dr. Seokhee Lee, Pusan Natl Univ., Korea - SL, Automation Dr. Dr Changsik Ha Pusan Natl Univ Korea Polymer Ha, Nat l Univ., Dr. Kyunghyun Choi, Cheju Natl Univ., Korea DW, Printed OLDE Dr. Hochan Kim, Andong Natl Univ., Korea Automation, Software development Dr. Dr Inhwan Lee Chungbuk Natl Univ Korea - SL Bioreactor Lee, Nat l Univ., SL,
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Acknowledgements
Several photos and materials has been obtained from W.M. Keck Center at UTEP ( (PI, Dr. Ryan Wicker). y ) Several photos has been copied from the Wikipedia website for better understanding. Several photos and materials has been obtained from the web-based lecture materials.
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Functional Micro/Macro Additive Manufacturing

Jae-Won Choi, Ph.D., Assistant Professor

Feel free to contact if you have any questions E-mail: palagent@gmail.com

Functional Micro/Macro Additive Manufacturing

J.W. Choi J.W. Choi

Innovative Design and Manufacturing Lab

Functional Micro/Macro Additive Manufacturing

J.W. Choi J.W. Choi

Introduction Additive Manufacturing Additi M f t i

Innovative Design and Manufacturing Lab

Functional Micro/Macro Additive Manufacturing

J.W. Choi J.W. Choi

Additive Manufacturing (AM)

Pre-production (Rapid Prototyping) to Rapid Manufacturing and Tooling. Coverage

Innovative Design and Manufacturing Lab

Functional Micro/Macro Additive Manufacturing

J.W. Choi J.W. Choi

Innovative Design and Manufacturing Lab

Functional Micro/Macro Additive Manufacturing

J.W. Choi J.W. Choi

Innovative Design and Manufacturing Lab

Functional Micro/Macro Additive Manufacturing

J.W. Choi J.W. Choi

Innovative Design and Manufacturing Lab

Functional Micro/Macro Additive Manufacturing

J.W. Choi J.W. Choi

Innovative Design and Manufacturing Lab

Functional Micro/Macro Additive Manufacturing

J.W. Choi J.W. Choi

Printing or joining process

Liquid polymerizati on process

Bonding of sheets with adhesive Laminated Object Manufacturing (LOM)

Bonding of sheets with light

Selective Laser Sintering (SLS)

Stereolithogr aphy (SL)

Multi-Jet Modeling (MJM)

Innovative Design and Manufacturing Lab

Functional Micro/Macro Additive Manufacturing

J.W. Choi J.W. Choi

Projects Review - Macro Additive

Innovative Design and Manufacturing Lab

Functional Micro/Macro Additive Manufacturing

J.W. Choi J.W. Choi

Micro channel Micro-channel Fabrication in SLA Using micro-wires in SLA

Build open micro-channel

Place micro-wire in channel

Complete build (embed wire)

Functional Micro/Macro Additive Manufacturing

J.W. Choi J.W. Choi

Build using material 1 Raise the platform

Rotate material vat 1 under build platform

Finished multiple material part

Manual Cleaning and drying the platform with a part

Rotate material vat 2 under build platform

Functional Micro/Macro Additive Manufacturing

J.W. Choi J.W. Choi

Functional Micro/Macro Additive Manufacturing

J.W. Choi J.W. Choi

Building the staircase, spirals, and top using the material 1

Applications (NGCs, medical models) 14

Innovative Design and Manufacturing Lab

Functional Micro/Macro Additive Manufacturing

J.W. Choi J.W. Choi