A systematic printability study of direct ink writing towards high-resolution rapid manufacturing
Direct ink writing (DIW) holds enormous potential in fabricating multiscale and multi-functional architectures by virtue of its wide range of printable materials, simple operation, and ease of rapid prototyping. Although it is well known that ink rheology and processing parameters have a direct impa...
| Main Authors: | , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
IOP Publishing
2023-01-01
|
| Series: | International Journal of Extreme Manufacturing |
| Subjects: | |
| Online Access: | https://doi.org/10.1088/2631-7990/acd090 |
| _version_ | 1797826076667281408 |
|---|---|
| author | Qingyang Zheng Bin Xie Zhoulong Xu Hao Wu |
| author_facet | Qingyang Zheng Bin Xie Zhoulong Xu Hao Wu |
| author_sort | Qingyang Zheng |
| collection | DOAJ |
| description | Direct ink writing (DIW) holds enormous potential in fabricating multiscale and multi-functional architectures by virtue of its wide range of printable materials, simple operation, and ease of rapid prototyping. Although it is well known that ink rheology and processing parameters have a direct impact on the resolution and shape of the printed objects, the underlying mechanisms of these key factors on the printability and quality of DIW technique remain poorly understood. To tackle this issue, we systematically analyzed the printability and quality through extrusion mechanism modeling and experimental validating. Hybrid non-Newtonian fluid inks were first prepared, and their rheological properties were measured. Then, finite element analysis of the whole DIW process was conducted to reveal the flow dynamics of these inks. The obtained optimal process parameters (ink rheology, applied pressure, printing speed, etc) were also validated by experiments where high-resolution (<100 μ m) patterns were fabricated rapidly (>70 mm s ^−1 ). Finally, as a process research demonstration, we printed a series of microstructures and circuit systems with hybrid inks and silver inks, showing the suitability of the printable process parameters. This study provides a strong quantitative illustration of the use of DIW for the high-speed preparation of high-resolution, high-precision samples. |
| first_indexed | 2024-03-13T11:03:20Z |
| format | Article |
| id | doaj.art-54d0f0c9b52b499e90a17bfe31b2054f |
| institution | Directory Open Access Journal |
| issn | 2631-7990 |
| language | English |
| last_indexed | 2024-03-13T11:03:20Z |
| publishDate | 2023-01-01 |
| publisher | IOP Publishing |
| record_format | Article |
| series | International Journal of Extreme Manufacturing |
| spelling | doaj.art-54d0f0c9b52b499e90a17bfe31b2054f2023-05-16T12:38:44ZengIOP PublishingInternational Journal of Extreme Manufacturing2631-79902023-01-015303500210.1088/2631-7990/acd090A systematic printability study of direct ink writing towards high-resolution rapid manufacturingQingyang Zheng0Bin Xie1Zhoulong Xu2Hao Wu3https://orcid.org/0000-0003-1494-0848Flexible Electronics Research Center, State Key Laboratory of Digital Manufacturing Equipment and Technology, School of Mechanical Science and Engineering, Huazhong University of Science and Technology , Wuhan, Hubei 430074, People’s Republic of ChinaFlexible Electronics Research Center, State Key Laboratory of Digital Manufacturing Equipment and Technology, School of Mechanical Science and Engineering, Huazhong University of Science and Technology , Wuhan, Hubei 430074, People’s Republic of ChinaGuangdong Sygole Intelligent Technology Co., Lt , Dongguan, Guangdong, People’s Republic of ChinaFlexible Electronics Research Center, State Key Laboratory of Digital Manufacturing Equipment and Technology, School of Mechanical Science and Engineering, Huazhong University of Science and Technology , Wuhan, Hubei 430074, People’s Republic of ChinaDirect ink writing (DIW) holds enormous potential in fabricating multiscale and multi-functional architectures by virtue of its wide range of printable materials, simple operation, and ease of rapid prototyping. Although it is well known that ink rheology and processing parameters have a direct impact on the resolution and shape of the printed objects, the underlying mechanisms of these key factors on the printability and quality of DIW technique remain poorly understood. To tackle this issue, we systematically analyzed the printability and quality through extrusion mechanism modeling and experimental validating. Hybrid non-Newtonian fluid inks were first prepared, and their rheological properties were measured. Then, finite element analysis of the whole DIW process was conducted to reveal the flow dynamics of these inks. The obtained optimal process parameters (ink rheology, applied pressure, printing speed, etc) were also validated by experiments where high-resolution (<100 μ m) patterns were fabricated rapidly (>70 mm s ^−1 ). Finally, as a process research demonstration, we printed a series of microstructures and circuit systems with hybrid inks and silver inks, showing the suitability of the printable process parameters. This study provides a strong quantitative illustration of the use of DIW for the high-speed preparation of high-resolution, high-precision samples.https://doi.org/10.1088/2631-7990/acd090direct ink writingextrusion mechanism modellingcomputational fluid dynamic (CFD)printability process parametershigh-resolution printing |
| spellingShingle | Qingyang Zheng Bin Xie Zhoulong Xu Hao Wu A systematic printability study of direct ink writing towards high-resolution rapid manufacturing International Journal of Extreme Manufacturing direct ink writing extrusion mechanism modelling computational fluid dynamic (CFD) printability process parameters high-resolution printing |
| title | A systematic printability study of direct ink writing towards high-resolution rapid manufacturing |
| title_full | A systematic printability study of direct ink writing towards high-resolution rapid manufacturing |
| title_fullStr | A systematic printability study of direct ink writing towards high-resolution rapid manufacturing |
| title_full_unstemmed | A systematic printability study of direct ink writing towards high-resolution rapid manufacturing |
| title_short | A systematic printability study of direct ink writing towards high-resolution rapid manufacturing |
| title_sort | systematic printability study of direct ink writing towards high resolution rapid manufacturing |
| topic | direct ink writing extrusion mechanism modelling computational fluid dynamic (CFD) printability process parameters high-resolution printing |
| url | https://doi.org/10.1088/2631-7990/acd090 |
| work_keys_str_mv | AT qingyangzheng asystematicprintabilitystudyofdirectinkwritingtowardshighresolutionrapidmanufacturing AT binxie asystematicprintabilitystudyofdirectinkwritingtowardshighresolutionrapidmanufacturing AT zhoulongxu asystematicprintabilitystudyofdirectinkwritingtowardshighresolutionrapidmanufacturing AT haowu asystematicprintabilitystudyofdirectinkwritingtowardshighresolutionrapidmanufacturing AT qingyangzheng systematicprintabilitystudyofdirectinkwritingtowardshighresolutionrapidmanufacturing AT binxie systematicprintabilitystudyofdirectinkwritingtowardshighresolutionrapidmanufacturing AT zhoulongxu systematicprintabilitystudyofdirectinkwritingtowardshighresolutionrapidmanufacturing AT haowu systematicprintabilitystudyofdirectinkwritingtowardshighresolutionrapidmanufacturing |