New York, NY—July 27, 2020—Additive manufacturing—or 3D printing—uses digital manufacturing processes to fabricate components that are light, strong, and require no special tooling to produce. Over the past decade, the field has experienced staggering growth, at a rate of more than 20% per year, printing pieces that range from aircraft components and car parts to medical and dental implants out of metals and engineering polymers. One of the most widely used manufacturing processes, selective laser sintering (SLS), prints parts out of micron-scale material powders using a laser: the laser heats the particles to the point where they fuse together to form a solid mass.

“Additive manufacturing is key to economic resilience,” say Hod Lipson, James and Sally Scapa Professor of Innovation (Mechanical Engineering). “All of us care about this technology—it’s going to save us. But there’s a catch.”

The catch is that SLS technologies have been limited to printing with a single material at a time: the entire part has to be made of just that one powder. “Now, let me ask you,” Lipson continues, “how many products are made of just one material? The limitations of printing in only one material has been haunting the industry and blocking its expansion, preventing it from reaching its full potential.”  

Wondering how to solve this challenge, Lipson and his PhD student John Whitehead used their expertise in robotics to develop a new approach to overcome these SLS limitations. By inverting the laser so that it points upwards, they invented a way to enable SLS to use—at the same time—multiple materials. Their working prototype, along with a print sample that contained two different materials in the same layer, was recently published online by Additive Manufacturing as part of its December 2020 issue.

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“Our initial results are exciting,” says Whitehead, the study’s lead author, “because they hint at a future where any part can be fabricated at the press of a button, where objects ranging from simple tools to more complex systems like robots can be removed from a printer fully formed, without the need for assembly.”

Selective laser sintering traditionally has involved fusing together material particles using a laser pointing downward into a heated print bed. A solid object is built from the bottom up, with the printer placing down a uniform layer of powder and using the laser to selectively fuse some material in the layer. The printer then deposits a second layer of powder onto the first layer, the laser fuses new material to the material in the previous layer, and the process is repeated over and over until the part is completed.

This process works well if there is just one material used in the printing process. But using multiple materials in a single print has been very challenging, because once the powder layer is deposited onto the bed, it cannot be unplaced, or replaced with a different powder.

“Also,” adds Whitehead, “in a standard printer, because each of the successive layers placed down are homogeneous, the unfused material obscures your view of the object being printed, until you remove the finished part at the end of the cycle. Think about excavation and how you can’t be sure the fossil is intact until you completely remove it from the surrounding dirt. This means that a print failure won’t necessarily be found until the print is completed, wasting time and money.”

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The researchers decided to find a way to eliminate the need for a powder bed entirely. They set up multiple transparent glass plates, each coated with a thin layer of a different plastic powder. They lowered a print platform onto the upper surface of one of the powders, and directed a laser beam up from below the plate and through the plate’s bottom. This process selectively sinters some powder onto the print platform in a pre-programmed pattern according to a virtual blueprint. The platform is then raised with the fused material, and moved to another plate, coated with a different powder, where the process is repeated. This allows multiple materials to either be incorporated into a single layer, or stacked. Meanwhile, the old, used-up plate is replenished. 

In the paper, the team demonstrated their working prototype by generating a 50 layer thick, 2.18mm sample out of thermoplastic polyurethane (TPU) powder with an average layer height of 43.6 microns and a multi-material nylon and TPU print with an average layer height of 71 microns. These parts demonstrated both the feasibility of the process and the capability to make stronger, denser materials by pressing the plate hard against the hanging part while sintering.

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“This technology has the potential to print embedded circuits, electromechanical components, and even robot components. It could make machine parts with graded alloys, whose material composition changes gradually from end to end, such as a turbine blade with one material used for the core and different material used for the surface coatings,” Lipson notes. “We think this will expand laser sintering towards a wider variety of industries by enabling the fabrication of complex multi-material parts without assembly. In other words, this could be key to moving the additive manufacturing industry from printing only passive uniform parts, towards printing active integrated systems.”

The researchers are now experimenting with metallic powders and resins in order to directly generate parts with a wider range of mechanical, electrical, and chemical properties than is possible with conventional SLS systems today.

Columbia Engineering

Columbia Engineering, based in New York City, is one of the top engineering schools in the U.S. and one of the oldest in the nation. Also known as The Fu Foundation School of Engineering and Applied Science, the School expands knowledge and advances technology through the pioneering research of its more than 220 faculty, while educating undergraduate and graduate students in a collaborative environment to become leaders informed by a firm foundation in engineering. The School’s faculty are at the center of the University’s cross-disciplinary research, contributing to the Data Science Institute, Earth Institute, Zuckerman Mind Brain Behavior Institute, Precision Medicine Initiative, and the Columbia Nano Initiative. Guided by its strategic vision, “Columbia Engineering for Humanity,” the School aims to translate ideas into innovations that foster a sustainable, healthy, secure, connected, and creative humanity.

ABOUT THE STUDY

The study is titled “Inverted multi-material laser sintering.”

Authors are: John Whitehead and Hod Lipson, Mechanical Engineering, Columbia Engineering.

The authors declare no financial or other conflicts of interest.

“Specifically, we found that potassium ions mitigate the formation of undesirable chemical compounds that deposit on the surface of lithium metal and prevent lithium ion transport during battery charging and discharging, ultimately limiting microstructural growth,” says the team’s PI Lauren Marbella, assistant professor of chemical engineering.

Her team’s discovery that alkali metal additives suppress the growth of non-conductive compounds on the surface of lithium metal differs from traditional electrolyte manipulation approaches, which have focused on depositing conductive polymers on the metal’s surface. The work is one of the first in-depth characterizations of the surface chemistry of lithium metal using NMR, and demonstrates the power of this technique to design new electrolytes for lithium metal. Marbella’s results were complemented with density functional theory (DFT) calculations performed by collaborators in the Viswanathan group in mechanical engineering at Carnegie Mellon University.

“Commercial electrolytes are a cocktail of carefully selected molecules,” Marbella notes. “Using NMR and computer simulations, we can finally understand how these unique electrolyte formulations improve lithium metal battery performance at the molecular level. This insight ultimately gives researchers the tools they need to optimize electrolyte design and enable stable lithium metal batteries.”

The team is now testing alkali metal additives that stop the formation of deleterious surface layers in combination with more traditional additives that encourage the growth of conductive layers on lithium metal. They are also actively using NMR to directly measure the rate of lithium transport through this layer.
 

Columbia Engineering

Columbia Engineering, based in New York City, is one of the top engineering schools in the U.S. and one of the oldest in the nation. Also known as The Fu Foundation School of Engineering and Applied Science, the School expands knowledge and advances technology through the pioneering research of its more than 220 faculty, while educating undergraduate and graduate students in a collaborative environment to become leaders informed by a firm foundation in engineering. The School’s faculty are at the center of the University’s cross-disciplinary research, contributing to the Data Science Institute, Earth Institute, Zuckerman Mind Brain Behavior Institute, Precision Medicine Initiative, and the Columbia Nano Initiative. Guided by its strategic vision, “Columbia Engineering for Humanity,” the School aims to translate ideas into innovations that foster a sustainable, healthy, secure, connected, and creative humanity.

ABOUT THE STUDY

The study is titled “Leveraging Cation Identity to Engineer Solid Electrolyte Interphases for Rechargeable Lithium Metal Anodes.” Authors are: Richard May 1; Yumin Zhang 1; Steven R. Denny 1; Venkatasubramanian Viswanathan 2,3; Lauren E. Marbella 1

1.  Department of Chemical Engineering, Columbia Engineering
2. Department of Materials Science and Engineering, Carnegie Mellon University
3. Department of Mechanical Engineering, Carnegie Mellon

The study was funded by the Alfred P. Sloan Foundation through a Scialog: Advanced Energy Storage Collaborative Innovation Award (2019-11419, LEM and VV). Richard May is supported by the U.S. Department of Defense through the National Defense Science & Engineering Graduate Fellowship Program.

The authors declare no competing interests.

Why knitting?

Most RF antennas, particularly highly directional array antennas like reflectarrays are planar, rigid devices. While these devices will likely always remain state-of-the-art in terms of pure performance metrics, they are often large, heavy, and unwieldy and can be expensive to manufacture. Researchers have been investigating ways to produce smaller, more flexible antennas, including inkjet printing or screen-printing directly on textiles, and embroidery. But these techniques are quasi-additive approaches in which a conductive material is added to an existing textile instead of being integrated into the textile during the fabrication process of the textile itself, introducing problems such as delamination, slip, or cracking of the metallic region, as well as issues of production scalability. 

Yu’s group realized that what they needed to create was a high-throughput, inexpensive technique that directly integrates flat array antennas onto textiles. So they decided to study knitting and weaving, which, while being the most common approaches for fabricating patterned textiles, have not been explored as a way to produce complex array antennas with engineered electromagnetic responses.

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A Fair Isle approach

The researchers took a novel approach to fabricating flexible, lightweight centimeter-wavelength metasurfaces. They leveraged an old-school colorwork knitting technique called float-jacquard knitting (think Fair Isle sweaters) and used commercially available metallic and dielectric yarns with existing knitting machinery to produce two prototype reflectarray devices, a metasurface lens (metalens) and a vortex-beam generating device. In the float-jacquard knitting technique, two or more types of yarn are used to produce a pattern: a yarn is floated loose beneath the fabric when not used and transferred back to the frontside as needed to create the desired pattern.

By integrating the textile fabrication and antenna patterning into a single process, the team streamlined the fabrication process and alleviated common defects in fabric-based antennas. The group is the first to adapt flat-knitting techniques to incorporate antennas directly during the fabric production procedure – integrated fabrication – and able to do it at low cost and high yield on an industrial scale. For example, each of the prototype metasurfaces with a footprint of approximately one square meter was knit within 45 minutes. In addition, the flat-knit fabric devices withstood repeated washing and stretching on a frame.

“The float-jacquard knitting technique used for making our textile metasurfaces is exactly the same technique that my mother used to make sweaters for me. I still remember a purple sweater I wore as a kid that had a row of white cats across the chest; I remember that when I inspected the inner side of the sweater, I saw white parallel yarns – the floats,” said Yu, a pioneer in researching nanophotonic devices like metasurfaces. 

He noted that these complex RF antennas can be readily produced by existing infrastructure: “We can leverage the very old and very well-established knitting industry to fulfill some of the needs of modern telecommunications. The facile and scalable nature of the fabrication approach means these devices could be inexpensive, ultra-lightweight, flexible variants of sophisticated radio-frequency communications antennas.”

The results 

The researchers showed experimentally that when the metalens operates as a receiving antenna, it focuses an incident centimeter-wave into a tight (diffraction-limited) focal spot, and that when it operates as a transmitting antenna, it converts the divergent emission from a horn antenna (a common RF source) into a wave with planar wavefront – a highly directional beam. 

They also demonstrated that more complex wavefront shaping tasks can be accomplished: the vortex-beam generating metasurface produces a vortex beam – a beam with a corkscrew-shaped wavefront. Because of the peculiar wavefront, the vortex beam can carry an independent channel of information, thus a vortex beam and a beam with planar wavefront used together can make a communications channel twice as efficient.

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Next steps

In future efforts, the researchers will explore modern knitting techniques – there are at least a dozen varieties – and knitting machines to realize more complex multi-functional designs – fabrics with combined designer electromagnetic, electronic, and mechanical responses. This could be used to engineer hinge points or folds, and electronic circuits into a fabric, which could be actuated to further facilitate stowage and deployment or even switch between different electromagnetic functionalities.

The scalability of flat knitting ranks highly among all techniques used to produce flexible or rigid RF metasurfaces and reflectarrays: commercial flat-knitting machines are capable of producing textiles up to two meters in width and with no limitation in the length direction. The researchers will explore this advantage to create high-gain antennas with apertures several meters in diameter yet lightweight and stowable to be carried by satellites to communicate across vast distances. 

“It’s important to stress that these devices were fabricated using commercially available off-the-shelf yarns and leveraging established fabrication techniques,” Yu said. “I am almost certain that communities of knitters can come up with ingenious ways to integrate aesthetics and functionality into a sweater – a sweater that can double as a WiFi signal booster.”

Media Credit: Jane Nisselson

About the Study

Journal: Advanced Materials

Title: Flat-Knit, Flexible, Textile Metasurfaces

Authors: Michael J. Carter^1,2, Leah Resneck³, Younes Ra'di^4,5, Nanfang Yu¹

1. Department of Applied Physics and Applied Mathematics, Columbia Engineering
2. Materials and Manufacturing Directorate, Air Force Research Laboratory, Wright-Patterson AFB
3. Zeis Textiles Extension, Wilson College of Textiles, North Carolina State University
4. Advanced Science Research Center, City University of New York
5. Department of Electrical Engineering and Computer Science, Syracuse University

Funding: The study was supported by the Science, Mathematics, and Research for Transformation (SMART) Scholarship of the US Department of Defense award to Michael Carter, and National Science Foundation grant (ECCS-2004685), awarded to Nanfang Yu. Measurements were carried out in mm-Wave Characterization Lab at the Advanced Science Research Center, the City University of New York. Devices were fabricated in the Knitting Lab (part of the Zeis Textiles Extension) at the Wilson College of Textiles, North Carolina State University

The authors have filed a provisional application for a patent with Columbia Technology Ventures based on the work reported in this article.