Printing Functional Materials Jennifer A. Lewis School of - - PowerPoint PPT Presentation

http://lewisgroup.seas harvard.edu

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Printing Functional Materials

Jennifer A. Lewis

School of Engineering and Applied Sciences Wyss Institute for Biologically Inspired Engineering Harvard University

NSF Additive Manufacturing Workshop – 07.11.13

Polymer inks !

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Broad range of commercial printers and solidification schemes (photocuring, !T, laser sintering, drying, etc.)

Stereolithography 3D Systems Laser Sintering 3D Systems Fused Deposition Stratasys PolyJet Process Objet Laser Net Shaping Optomec Electron Beam Melting Arcam 3D Printing Z Corp Robocasting Robocasting Enterprises

3D Printing – Design, Print, Innovate

Broad range of commercial printers and solidification schemes (photocuring, !T, laser sintering, drying, etc.)

Stereolithography 3D Systems Laser Sintering 3D Systems Fused Deposition Stratasys PolyJet Process Objet Laser Net Shaping Optomec Electron Beam Melting Arcam 3D Printing Z Corp Robocasting Robocasting Enterprises

3D Printing – Design, Print, Innovate

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Several advances needed for 3D printing of high performance, functional materials !

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Ø Broaden materials palette for 3DP Ø Integration of multiple materials Ø Digitally specify form and function Ø Improve feature resolution by 100x Ø Improve throughput by 100x

Our research focus ¡

… ¡expedite ¡transformation ¡from ¡rapid ¡prototyping ¡ ¡ to ¡manufacturing ¡of ¡functional ¡materials ¡

10x10x5 cm3 ± 50 nm ! ! !1m2x10 cm ± 5 µm! V = 0.1 -10 mm/s ! ! ! !V = 1 -1000 mm/s !!

Moderate Area, High Precision! Large Area, High Speed Stage!

Custom stages designed for 3D printing

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Ink filament printing! ! continuous filament! is extruded through ! deposition nozzle!

Printing ink filaments (in and out of plane)

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V*12-.+%2)?!()*+%*+,! \+271.!%#!).%2*+! B12-.+%2)?!$/2(.! $#1*0[1*4.! $/.2)! %/*++*+,!

Desired Ink Rheology:

• " Shear thinning behavior facilitates

flow through fine nozzles without clogging

• " Viscoelastic behavior enables

printing of self-supporting (spanning) features &D!-*3)#+!+#]]1.!

Ink design and deposition

• ink must flow through nozzle without jamming
• ink filaments must form high integrity interfaces
• ink must solidify rapidly (via gelation, coagulation, or evaporation)
• concentrated inks minimize shrinkage during drying

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/01*µ2* /01*(2*

colloidal inks! sol-gel inks! polyelectrolyte inks! fugitive inks! nanoparticle inks!

Viscoelastic inks designed for 3D printing

Reactive silver inks for integrated electronics

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Silver particle inks for integrated electronics

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Silver inks are highly conductive as-printed

Silver particle inks for printed electronics

Solar panels - present design

Rigid, costly, active materials* occupy large area

*silicon PV cells and silver interconnects

fK!XW!3.11!

100 µm interconnects

78$72)$!

Printing High Aspect Ratio Silver Microelectrodes!

1 µm nozzle 5 µm nozzle 10 µm nozzle

30 µm nozzle 5 µm nozzle 10 µm nozzle 5 µm nozzle 10 µm nozzle 30 µm nozzle

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Flexible photovoltaics

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g+%.)3#++.3%$! &D!µ-!! +#]]1.! G8$!72)$! f;D!µ-!! +#]]1.!

30 µm nozzle 610 µm nozzle

Sparse array of PV cells; finer interconnects ! g+X!3.11$! g+%.)3#++.3%$! 10 cmx10 cm g+!3#1127#)2%*#+!6*%/!Y.-()*8$!2+0!YAgO!

Printing interconnects and bus bars

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Printed interconnects are highly flexible and can withstand repeated bending (1000’s cycles) without performance loss Printed interconnects exhibit excellent I-V response

6” polyimide substrate

Flexible concentrator photovoltaics

"ink~1x10-5 #•cm (after 30 min @ 175°C)

Sheet resistance = 30 m#/sq

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Conformal printing of electrically small antennas

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Performance characteristics

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Embedded Electronics (carbon ink printed in polymer matrix) !

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Embedded Electronics (carbon ink printed in polymer matrix) ¡

Strain ¡Gage ¡ Length ¡= ¡20 ¡mm ¡ ¡ All ¡printed ¡ sequentially ¡in ¡ 1mm ¡thick ¡ EcoFlex ¡reservoir ¡ with ¡the ¡Wood ¡group ¡

3D Printed of Strain Gage Arrays

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Printed Three-Layer Stretchable Sensors

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For autonomous devices that:

• 1. Harvest energy
• photovoltaic
• thermoelectric
• piezoelectric!
• 2. Store energy
• micro-batteries w/ high energy

and power density

• 3. Perform function
• Mechanical
• Sensing
• RF

Energy ! Harvesting! Energy ! Emission! Energy ! Storage! Control!

Aim: Print Microbatteries w/ High Power & Energy Density

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Warneke et al., Computer 2001! Lai et al., Adv. Mater. 2010!

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Key Factors Influencing Power & Energy Density

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Printing 3D Interdigitated Microbatteries!

LTO ! LFP! c) Current collector (Au) ! Glass! a) Nozzle (30 µm) ! b) LTO ! Packaging ! d)

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Ink Viscosity and Elastic Modulus ¡

LFP ¡ink ¡(cathode) ¡ LTO ¡ink ¡(anode) ¡ Ink ¡rheology ¡tailored ¡for ¡3D ¡filamentary ¡printing ¡

• K. ¡Sun, ¡Lewis, ¡Dillon ¡et ¡al, ¡Adv. ¡Mater. ¡2013 ¡

Printing High Aspect Ratio Structures!

Y2+0!,)2*+$!

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[!!.23/!-*3)#72%%.)?!.p8*H21.+%!*+!$*].!%#!2!$*+,1.!,)2*+!#5!$2+0!

200 µm 300 µm

Printed 3D Interdigitated Microbattery ¡

• K. ¡Sun, ¡Lewis, ¡Dillon ¡et ¡al, ¡Adv. ¡Mater. ¡2013 ¡

Printed and Packaged 3D Microbattery ¡

200 µm

• K. ¡Sun, ¡Lewis, ¡Dillon ¡et ¡al, ¡Adv. ¡Mater. ¡2013 ¡

LFP-LTO Full Cell Properties ¡

• K. ¡Sun, ¡Lewis, ¡Dillon ¡et ¡al, ¡Adv. ¡Mater. ¡2013 ¡

Microbattery Performance!

Z.5!&S9!O/*2+,!:"gv<!! &'[g"A!:_.6*$I!'*11#+<!

Z.5!&M9!G)28+I!o*+,!:\g\O<!!

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High throughput 3D printing

3;! <;! @'!

5 mm 1 mm 200 μm

All 64 nozzles are 205±3 µm on a side

Multinozzle design based on Murray’s law: Hierarchical branching network Created by CNC milling

! rparent

3

= r

branch _ generation 3

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High throughput printing of 3D architectures

Periodic polymer foam

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'821!-81%*+#]]1.!()*+%/.20! 3D Interpenetrating Architectures!

!" Created model and functional inks with controlled flow behavior !" Printed flexible electronics, photovoltaics, and sensors from conductive inks !" Printed 3D Li-ion microbatteries !" Implemented new multimaterial 3D printing !" Designed and implemented microvascular nozzle arrays for high throughput printing

Summary

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Thank you!

http://lewisgroup.seas harvard.edu

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