Car radars, 5G communication systems and satellite-based atmospheric sensors could all be improved as a result of a UK project to develop 3D printed terahertz and microwave circuits.
Although 3D printing is widely used in many areas of manufacturing, its use in microwave and terahertz circuits has so far been limited by the level of precision required to build devices at such a small scale.
However, the accuracy of 3D printers has significantly improved in recent years, with some now able to print down to a resolution of five microns or less, according to Michael Lancaster at Birmingham University, who is leading the EPSRC-funded project.
Russian researchers have used machine learning to make metal 3D printing more efficient.
3D printers require fine tuning of positioning and control algorithms using mathematical models to reach optimal performance. This is a lengthy and arduous process and it could take weeks to set printing parameters. Even then, the possibility of printing error is always present.
To overcome such problems scientists at the Laboratory of Lightweight Materials and Structures of Peter the Great St. Petersburg Polytechnic University (SPbPU) have developed a neural network for a metal 3D printer.
LONDON (ICIS)–The true take off for 3D printing is on the horizon but a lack of machinery capable of production is holding the technology back, according to Evonik’s head of new 3D technologies.
Sylvia Monsheimer said that, while the company is happy with the growth it has seen in the 3D printing industry in the last 20 years, there is a lack of machinery capable of production available on the market.
Patients waiting for an organ transplant may soon have a new treatment option — print out the organ or tissue they need using a revolutionary form of 3D printing that may one may day eliminate the need to wait on transplant donations.
Organovo, a biotech company in San Diego is leading the revolution in bioprinting and Boston area researchers are weighing the benefits of 3D-printed tissue.
“It’s about personalized and customized treatment,” said Xuanhe Zhao, a professor of mechanical engineering at Massachusetts Institute of Technology. He said 3D printing could eventually eliminate the need for transplant donations.
A team of researchers at RMIT University (Melbourne, Australia) is using laser metal deposition technology (a 3D printing technique) to build and repair defense aircraft parts in a two-year collaboration with RUAG Australia (Bayswater, Australia) and the Innovative Manufacturing Cooperative Research Centre (IMCRC; Carlton, Australia).
Laser metal deposition technology feeds metal powder into a laser beam, which when scanned across a surface adds new material in a precise, web-like formation. The metallurgical bond created has mechanical properties similar, or in some cases superior, to those of the original material. “It’s basically a very high-tech welding process where we make or rebuild metal parts layer by layer,” explains Professor Milan Brandt, who is leading the work. He says the concept is proven and prospects for its successful development are extremely positive.
A recent series of major developments and events has created a new impetus for 3D printing plastic recycling. 3D printing of recycled plastics has multiple benefits, including lower costs and control over the amount of materials that can be used by 3D printers. Currently, 3D printing filament is produced by melting down virgin plastic pellets and extruding the melted plastic through a circular die which is then rolled up into spools. Printing with pellets or recycled materials is more cost effective and energy efficient than printing with new plastic filaments. In addition, direct printing of plastic pellets eliminates the need for further processing and therefore makes them less expensive.
Plastic has always been one of the leading 3D printer material categories. Now there is an expanding global concern about the amount of plastic product waste and in particular its negative impact on oceans and waterways. Improved pellet 3D printing recycling technology can play an important part in helping solve this environmental problem. 3D printing product developers, engineers, designers and environmentalists working on pellet recycling projects have the opportunity to earn US R&D tax credits.
Researchers from RMIT University in Melbourne have been using laser metal-deposition technology to build and repair defence aircraft in a process that’s similar to 3D printing.
The team believes the technology could be “game-changing” for the aviation industry
“It’s basically a very high-tech welding process where we make or rebuild metal parts layer by layer,” said Professor Milan Brandt who is working on the project.
How to leverage additive manufacturing to build better products
Architects don’t build without modelling. They create “blueprints,” produce renderings, and build 3D models. But while these planning tools may resemble the actual building in shape, there is no resemblance in size or materials. As a result, except in the case of manufactured or modular buildings, the finished product will be the first time that real building materials have come together in exactly that configuration. That is one of the reason that architecture tends to be conservative in its rate of change. Without real-world testing, big change is risky.
Rapid prototyping technology, building parts by creating a series of successive layers, began in the 1980s in Japan and immediately became a subject of interest in the U.S. The first patent, which coined the term stereo lithography (SLA), was granted in 1986 to Chuck Hull in the U.S. His 3D Systems company created the first prototype equipment in 1987 and launched the first commercial equipment in 1988.
Metal AM Beginnings: By the early 1990s, a half-dozen technologies based on layering principles were in the early stages of commercialization. Many subsequent approaches evolved from using liquids as the base material to using powders. Until the advent of powders, it was technically impossible to consider metal prototypes. The race to achieve metal prototypes now began. Twenty-five years later, the industry has achieved metal additive prototypes and is on the cusp of widespread Metal Additive Manufacturing (Metal AM).