Towards Advanced Nanoscale Additive Manufacturing (AM) of Metals: A Fundamental Theoretical, Multi-Physics Simulation and in situ Electron Microscopy Approach
Abstract
Department of Mechanical Engineering, NanoTech Institute, University of Texas at Dallas Research Problem: With the ever increasing miniaturization trend, one of the current challenges in additive manufacturing (AM) is the extent to which we can push the size-limit of additive manufacturing of metals. Can true nanoscale resolution be achieved? What are the fundamental scientific questions that need to be answered? Metal conductors are the essential component of any devices. Current 3D printers are constrained to thermoplastics or UV-curable resins. The extrusion-based methods (for example, Dr. Lewis group at Harvard) are limited to microscale, since the minimum nozzle-size, and hence the size of the structures are ultimately limited by the finite size of the colloidal particles in the ink. This forward-looking proposal addresses this critical problem, and puts forward a research plan based on a combined theoretical, simulation, and experimental approach to enable direct „writing? of high aspect-ratio pure metallic features with 30 nm in resolution in freely suspended 3D arrangements backed up by solid preliminary data to ensure the success of the proposed research. Technical Approaches: This proposal is focused on fundamental investigation of a novel additive manufacturing process based on nanoscale electrodeposition. The core concept is physically confining the electrodeposition process to a small electrolyte “meniscus” region at the aperture of a dispensing nozzle. This electrolyte-containing nozzle is precisely steered in 3D by piezo-positioners directly guided by a CAD (computer-aided design) model, which ultimately forms desired nanoscale 3D solid structures in an atom-by-atom process. This inherently multi-physics process includes electric field-induced nanofluidics, hydrodynamics and diffusion mass transport, evaporation heat transfer, electric double-layer, and electroplating and crystallization processes all occurring simultaneously within a nanoscale area. This research will systematically investigate the effect of manufacturing processing parameters on the process outputs including ultimate achievable deposition rate, feature resolution, microstructural, and electro-mechanical properties of the structures using state-of-the-art in situ electron microscopy experiments. Anticipated Outcomes: Key outcomes include (i) fundamental new knowledge on multi-physics additive manufacturing process at the nanoscale, and (ii) the first ever ambient environment nanoscale additive manufacturing technology for metals with 30 nm resolution. Impacts on Navy’s Capabilities: The proposed nanoscale additive manufacturing process will contribute to the Naval S&T focus areas, in particular to (i) Autonomy and Unmanned Systems, (ii) Power and Energy, and (iii) Warfighter Performance. In addition, it is in-line with the National Science and Technology Priorities areas and National Strategic Plan for Advanced Manufacturing for creating industries of the future. Specific applications would include manufacturing of 3D nano-electronic devices, nano-sensors, electromagnetic helical antennas for terahertz (THz) communications, interconnects for stacked integrated circuits, and nano-robotics. As such, this Nano AM process has the potential to transform the US warfighter?s capabilities through miniaturization of devices and achieving compact and light-weight military components. Government-Industry-Academia Partnership: Dallas (TX) is home to several major defense industries including Lockheed Martin (LM), Raytheon and Bell Helicopter. Given the PI’s current AFOSR-YIP project, the PI commits to develop a partnership between his academic group, the Navy and other DoD labs, and leading defense industries. (Letter from LM attached).
Document Details
- Document Type
- DoD Grant Award
- Publication Date
- Aug 12, 2016
- Source ID
- N000141512795
Entities
People
- Majid Minary Jolandan
Organizations
- Office of Naval Research
- United States Navy
- University of Texas at Dallas