Polymeric Microfluidic Fuel Cells with Controlled Printed Patterns.

Since its first appearance almost a couple of decades ago, microfluidic fuel cells (MFFCs) have gained considerable research momentum due to their potential applications in portable devices. The main focus has been on the effective fabrication of microfluidic channels with different materials, where the manufacturing limitations proved to be the main stumbling blocks. Paper-based MFFCs have been reported with some success, where the porosity of the flow channel medium drives the reactants, greatly reducing the need for elaborate external devices and complex manufacturing obstacles, although the longevity of these cells remains questionable.

Generative Design of Structured Materials for Controlled Frequency Responses.

Spatially varying material properties allow the dynamic response of structural systems to be almost arbitrarily tailored, far beyond the first or fundamental natural frequency. Continuing advances in manufacturing technology are making it possible to achieve the necessary range of stiffness and density variations, but the design of these property distributions is a challenging task because of the complex multidimensional nature of the problem. Generative design methods based on evolutionary optimization algorithms have been successfully used to obtain solutions based on multi-material distributions.

Structural optimisation for controlled deflections of additively manufactured single material beams.

Closely controlling the mechanical behaviour and characterization of the deflection of a beam structure is a well-known and widely studied engineering problem. The progress in additive manufacturing methods and the possibilities to closely control the material property variations with the controlled placement of materials further widen the opportunities to achieve given beam deflection criteria. The multi-material additive manufacturing solutions suffer from the lack of real engineering material options, and the quality and performance of the printed parts are usually unsuitable for producing functional parts.

Experimental Evaluation of Polyphenylsulfone (PPSF) Powders as Fire-Retardant Materials for Processing by Selective Laser Sintering.

Additive manufacturing has progressed rapidly, and the unique attributes of the layer-wise material consolidation are attracting ever increasing application potentials in critical sectors such as medical and aerospace industries. A lack of materials options has been the main bottleneck for the much wider uptake of these promising new technologies. Inventing new material alternatives has been central to most of the research attention in additive manufacturing in recent times.

Enhanced biomechanical performance of additively manufactured Ti-6Al-4V bone plates.

As the global trauma fixation devices market expands rapidly, it is imperative to improve the production of fixation devices through enhanced design accuracy and fit for best performance and maximum patient comfort. Selective laser melting (SLM) is one of the mature additive manufacturing methods, which provides a viable route for the rapid production of such devices. In this work, the ability of SLM to produce near-net-shape parts, as desired for medical implants, was utilized for the fabrication of bone plates from Ti-6Al-4V alloy powder.

Artificial Evolution and Design for Multi-Material Additive Manufacturing.

Limitations of the traditional manufacturing methods often force engineered components to be made of single material systems. However, this is going through changes due to the advent of additive manufacturing (AM) methods, as the point-by-point consolidation allows for a possible change of the material constitution within a given part domain. This will give rise to a plethora of new material and property options for the designers, where just human perception may fail to realize the full benefits.

Extrusion 3D Printing of Polybutyrate-Adipate-Terephthalate-Polymer Composites in the Pellet Form.

Fused deposition modelling is a common 3D printing technique used for the freeform fabrication of complex shapes based on polymers. Acrylonitrile butadiene styrene (ABS) is the common material option, though polylactide (PLA) has also proved to be a successful candidate. There is an ever increasing demand to harness new materials as possible candidates for fused deposition.

Selective Laser Sintering of Nano Al₂O₃ Infused Polyamide.

Nano Al₂O₃ polyamide composites are evaluated for processing by selective laser sintering. A thermal characterization of the polymer composite powders allowed us to establish the possible initial settings. Initial experiments are conducted to identify the most suitable combinations of process parameters.

Manufacturing the Gas Diffusion Layer for PEM Fuel Cell Using a Novel 3D Printing Technique and Critical Assessment of the Challenges Encountered.

The conventional gas diffusion layer (GDL) of polymer electrolyte membrane (PEM) fuel cells incorporates a carbon-based substrate, which suffers from electrochemical oxidation as well as mechanical degradation, resulting in reduced durability and performance. In addition, it involves a complex manufacturing process to produce it. The proposed technique aims to resolve both these issues by an advanced 3D printing technique, namely selective laser sintering (SLS).