Drop-on-demand metal jetting of pure copper: On the interaction of molten metal with ceramic and metallic substrates

Copper, renowned for its exceptional electrical and thermal conductivity at a low cost, holds great promise in electronic applications. While additive manufacturing of copper has attracted interest, the exploration of applying Drop-on-demand Metal Jetting (DoD-MJ) to 3D print pure copper remains uncharted. To fill this research gap, we employed an in-house DoD-MJ platform, MetalJet, to generate Cu microdroplets and deposit them onto ceramic and metallic substrates, a first-time achievement in this research context. Our study demonstrates the successful generation of uniform Cu microdroplets, emphasising the pivotal role of oxygen content control in preventing nozzle-level reactions, a factor that can disrupt droplet formation. Both alumina and aluminium nitride substrates exhibited poor wettability with molten Cu droplets, and no interface formed between these surfaces due to thermodynamically unfavourable reactions. Nevertheless, the irregular surface of alumina displayed an interesting capability to enable the adhesion of Cu droplets to the substrate through an interlocking mechanism. Lastly, the electrical resistivity of MetalJet printed pillars was measured as low as 6.75×10-8Ωm without any post-treatment, offering exciting possibilities for applications in 3D electronics

From impact to solidification in drop-on-demand metal additive manufacturing using MetalJet

Drop-on-demand metal jetting is a promising additive manufacturing (AM) technology that is gaining interest due to its capability to directly print complex single and multi-material components at high resolutions. It also has key advantages over other metal AM techniques, such as avoiding powder handling and extensive post-processing. In this method, parts are built via spatially controlled deposition of individual molten droplets onto a substrate. Therefore, the success of the process entirely depends on the behaviour of these single droplets from deposition to solidification including their interactions with the substrate, which is scarcely investigated to date. To fill this research gap, the in-house MetalJet platform was used to investigate the spreading and solidification of metallic micro-droplets at low Weber numbers. This was undertaken onto various substrates using a range of jetting and substrate temperatures through an integrated experimental, analytical, and computational approach. This study reports that increasing the substrate temperature enhanced the diffusion between the droplet and substrate, hence improving the bonding. Moreover, ripples forming on a droplet’s periphery during solidification disappeared at elevated substrate temperatures, resulting in improved inter-droplet bonding. Furthermore, the significant role of the substrate wettability and thermal properties, which control the droplet’s dynamics and solidification behaviour, respectively, is elucidated. This highlights the importance of substrate material selection using this technology. The results presented in this article underpin the optimal process conditions under which the 3D structures produced with this technology can exhibit reliable integrity and consistency. This represents a step forward in the direct metal printing of high resolution functional multi-material components

A comparison of Ti-6Al-4V in-situ alloying in Selective Laser Melting using simply-mixed and satellited powder blend feedstocks

In-situ alloying within laser powder-bed fusion, specifically Selective Laser Melting (SLM), has been investigated for the formulation of novel alloys from elemental powders to extend the benefits offered by these technologies. Inadequate preparation of the powder feedstock prior to in-situ alloying can yield inhomogeneous microstructures, often deteriorating the mechanical performance of the deposited parts. The present work was designed to assess the use of the ‘satelliting’ method to create powder feedstocks for in-situ laser powder-bed fusion. The research was carried out on Ti-6Al-4V. Ti-6Al-4V feedstocks obtained by mixing or satelliting elemental powders were investigated and compared to a reference pre-alloyed material. The processability of the different feedstocks was assessed by comparing the microstructure of the deposits originating from the different powder blends. Results show that the powder percolation and particle size distribution of the feedstocks translate in deposited microstructures exhibiting different porosity, elemental segregation, and average grain size, revealing the impact of the powder blend characteristics on the laser energy absorbance and solidification of the alloy. This study provides fundamental insights of how to formulate powder feedstock and aims to support future research activities on the design and development of new alloys for use in powder-based additive manufacturing

Evolution of carbon nanotubes and their metallurgical reactions in Al-based composites in response to laser irradiation during selective laser melting

Aluminium-based composites reinforced with carbon nanotubes are widely sought for their outstanding metallurgical and structural properties that largely depend on the manufacturing route. In this work, the process-structure-property relationship for a composite made from high-energy-ball-milled pure Al and multi-walled carbon nanotubes (MWCNT) processed by laser powder-bed-fusion additive manufacturing was investigated. The response of MWCNT to laser irradiation and their interfacial reactions with Al were probed in a holistic investigation. X-ray diffraction confirmed the partial transformation of C into Al-carbides in addition to the presence of some nano-crystalline graphitic materials. Microscopy revealed evidence of carbides segregation at the melt pool boundaries as well as migration along the build direction. Raman spectroscopy showed that laser irradiation promoted re-graphitisation in MWCNT, reducing the amount of defects introduced by milling. Two types of Al4C3 formed as a result of the metallurgical reaction between Al and MWCNT. These were needle-like and hexagonal Al4C3 and their mechanisms of formation, direct precipitation and dissolution-precipitation, respectively, were explained in light of the thermal profile experienced by the material during melting and solidification. Large scale electron backscatter diffraction showed that there is no distinctive texture developing during melting and solidification. Micro- and nano-indentation testing showed uniform mechanical properties

Development of a genotyping microarray for Usher syndrome

BACKGROUND: Usher syndrome, a combination of retinitis pigmentosa (RP) and sensorineural hearing loss with or without vestibular dysfunction, displays a high degree of clinical and genetic heterogeneity. Three clinical subtypes can be distinguished, based on the age of onset and severity of the hearing impairment, and the presence or absence of vestibular abnormalities. Thus far, eight genes have been implicated in the syndrome, together comprising 347 protein-coding exons. METHODS: To improve DNA diagnostics for patients with Usher syndrome, we developed a genotyping microarray based on the arrayed primer extension (APEX) method. Allele-specific oligonucleotides corresponding to all 298 Usher syndrome-associated sequence variants known to date, 76 of which are novel, were arrayed. RESULTS: Approximately half of these variants were validated using original patient DNAs, which yielded an accuracy of >98%. The efficiency of the Usher genotyping microarray was tested using DNAs from 370 unrelated European and American patients with Usher syndrome. Sequence variants were identified in 64/140 (46%) patients with Usher syndrome type I, 45/189 (24%) patients with Usher syndrome type II, 6/21 (29%) patients with Usher syndrome type III and 6/20 (30%) patients with atypical Usher syndrome. The chip also identified two novel sequence variants, c.400C>T (p.R134X) in PCDH15 and c.1606T>C (p.C536S) in USH2A. CONCLUSION: The Usher genotyping microarray is a versatile and affordable screening tool for Usher syndrome. Its efficiency will improve with the addition of novel sequence variants with minimal extra costs, making it a very useful first-pass screening tool

Off the Grid: a new strategy for material-jet 3D printing with enhanced sub-droplet resolution

Drop-on-Demand additive manufacturing could offer a facile solution for scalable on-site manufacturing. With an increasing number of functional materials available for this technology, there are growing opportunities for applications, such as electronics. Here we report on a novel printing strategy, Off-the-Grid (OtG), which enables refined positioning of individual droplets and enhanced resolution compared to the traditional printing strategy. We demonstrate successful printing of structures with feature position control smaller than a single droplet size, and hence enhanced shape fidelity for intricate designs. This strategy is extended to filled patterns, enabling improved layer coverage and customisable inter-layer droplet positioning to control surface morphology. The OtG strategy is applied to produce functional designs, such as conformable circuitry and miniaturized antennae, and is transferable to different materials, from metal nanoparticle and polymeric inks on inkjet platforms, to molten metals on a MetalJet printer. These results could advance exploitation of AM in electronic

Melanocortin receptor agonists MCR1-5 protect photoreceptors from high-glucose damage and restore antioxidant enzymes in primary retinal cell culture

Retinal photoreceptors are particularly vulnerable to local high-glucose concentrations. Oxidative stress is a risk factor for diabetic retinopathy development. Melanocortin receptors represent a family of G-protein-coupled receptors classified in five subtypes and are expressed in retina. Our previous data indicate that subtypes 1 and 5 receptor agonists exert a protective role on experimental diabetic retinopathy. This study focuses on their role in primary retinal cell cultures in high-glucose concentrations. After eye enucleation from wild-type male C57BL/6 mice, retinal cells were isolated, plated in high-glucose concentration and treated with melanocortin receptors 1 and 5 agonists and antagonists. Immunocytochemical and biochemical analysis showed that treatment with melanocortin receptors 1 and 5 agonists reduced anti-inflammatory cytokines and chemokines and enhanced manganese superoxide dismutase and glutathione peroxidase levels, preserving photoreceptor integrity. According with these evidences, we propose a major role of melanocortin receptors 1 and 5 on primary retinal cell response against high glucose or oxidative insults.Retinal photoreceptors are particularly vulnerable to local high-glucose concentrations. Oxidative stress is a risk factor for diabetic retinopathy development. Melanocortin receptors represent a family of G-protein-coupled receptors classified in five subtypes and are expressed in retina. Our previous data indicate that subtypes 1 and 5 receptor agonists exert a protective role on experimental diabetic retinopathy. This study focuses on their role in primary retinal cell cultures in high-glucose concentrations. After eye enucleation from wild-type male C57BL/6 mice, retinal cells were isolated, plated in high-glucose concentration and treated with melanocortin receptors 1 and 5 agonists and antagonists. Immunocytochemical and biochemical analysis showed that treatment with melanocortin receptors 1 and 5 agonists reduced anti-inflammatory cytokines and chemokines and enhanced manganese superoxide dismutase and glutathione peroxidase levels, preserving photoreceptor integrity. According with these evidences, we propose a major role of melanocortin receptors 1 and 5 on primary retinal cell response against high glucose or oxidative insults