Selective Sheet Extrusion: A Novel Manufacturing Process for Large-Format Material Extrusion

IF 4.3 3区材料科学 Q1 ENGINEERING, ELECTRICAL & ELECTRONIC

ACS Applied Electronic Materials Pub Date : 2024-07-05 DOI:10.3390/jmmp8040145

Brian Parrott, Angelica Coronado Preciado, Eric Feron

{"title":"Selective Sheet Extrusion: A Novel Manufacturing Process for Large-Format Material Extrusion","authors":"Brian Parrott, Angelica Coronado Preciado, Eric Feron","doi":"10.3390/jmmp8040145","DOIUrl":null,"url":null,"abstract":"The trade-off between resolution and speed represents a significant challenge when extrusion-based additive manufacturing (AM) is used for large-format additive manufacturing (LFAM). This paper presents an analysis of a new material extrusion process, named selective sheet extrusion (SSE), that aims to decouple these parameters. Unlike traditional single-nozzle material extrusion processes, SSE utilizes a single, very wide nozzle through which extrusion is controlled by an array of dynamically actuated teeth at the nozzle outlet. This allows the system to deposit a selectively structured sheet of material with each pass, potentially enabling the deposition of an entire layer of a part in a single pass. An analysis of the theoretical performance of the SSE technology, in terms of speed and material efficiency in comparison with single-nozzle extrusion systems, predicted speed increases of 2–3 times for the geometries that were explored. The analysis was then validated through experimental work that indicated a normalized improvement in print speed of between 2.3 and 2.5 times using a proof-of-concept SSE prototype. The SSE concept expands the opportunity frontier of LFAM technologies by enabling enhanced print speeds, while maintaining higher resolutions at scale. This enhancement in speed and/or resolution could have significant benefits, especially in large-scale prints that benefit from enhanced internal resolution.","PeriodicalId":3,"journal":{"name":"ACS Applied Electronic Materials","volume":" 10","pages":""},"PeriodicalIF":4.3000,"publicationDate":"2024-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"ACS Applied Electronic Materials","FirstCategoryId":"1085","ListUrlMain":"https://doi.org/10.3390/jmmp8040145","RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q1","JCRName":"ENGINEERING, ELECTRICAL & ELECTRONIC","Score":null,"Total":0}

引用次数: 0

Abstract

The trade-off between resolution and speed represents a significant challenge when extrusion-based additive manufacturing (AM) is used for large-format additive manufacturing (LFAM). This paper presents an analysis of a new material extrusion process, named selective sheet extrusion (SSE), that aims to decouple these parameters. Unlike traditional single-nozzle material extrusion processes, SSE utilizes a single, very wide nozzle through which extrusion is controlled by an array of dynamically actuated teeth at the nozzle outlet. This allows the system to deposit a selectively structured sheet of material with each pass, potentially enabling the deposition of an entire layer of a part in a single pass. An analysis of the theoretical performance of the SSE technology, in terms of speed and material efficiency in comparison with single-nozzle extrusion systems, predicted speed increases of 2–3 times for the geometries that were explored. The analysis was then validated through experimental work that indicated a normalized improvement in print speed of between 2.3 and 2.5 times using a proof-of-concept SSE prototype. The SSE concept expands the opportunity frontier of LFAM technologies by enabling enhanced print speeds, while maintaining higher resolutions at scale. This enhancement in speed and/or resolution could have significant benefits, especially in large-scale prints that benefit from enhanced internal resolution.

查看原文本刊更多论文

选择性片材挤压：用于大型材料挤压的新型制造工艺

当基于挤压的增材制造（AM）用于大幅面增材制造（LFAM）时，分辨率和速度之间的权衡是一项重大挑战。本文分析了一种新的材料挤压工艺，即选择性片材挤压工艺（SSE），其目的是将这些参数分离开来。与传统的单喷嘴材料挤压工艺不同，SSE 利用一个非常宽的单喷嘴，通过喷嘴出口处的动态驱动齿阵列控制挤压。这样，该系统每次通过时都能沉积出有选择性结构的材料片，从而有可能在一次通过中沉积出零件的整个层。与单喷嘴挤出系统相比，SSE 技术在速度和材料效率方面的理论性能分析表明，所研究的几何形状的速度可提高 2-3 倍。随后，通过实验工作对分析结果进行了验证，实验结果表明，使用概念验证 SSE 原型，印刷速度正常化提高了 2.3 至 2.5 倍。SSE 概念可提高打印速度，同时保持更高的规模分辨率，从而拓展了 LFAM 技术的机遇领域。速度和/或分辨率的提高可以带来显著的效益，特别是在受益于内部分辨率提高的大规模印刷中。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

求助全文

约1分钟内获得全文求助全文

来源期刊

ACS Applied Electronic Materials Multiple-

CiteScore

7.20

自引率

4.30%

发文量

567

期刊介绍： ACS Applied Electronic Materials is an interdisciplinary journal publishing original research covering all aspects of electronic materials. The journal is devoted to reports of new and original experimental and theoretical research of an applied nature that integrate knowledge in the areas of materials science, engineering, optics, physics, and chemistry into important applications of electronic materials. Sample research topics that span the journal's scope are inorganic, organic, ionic and polymeric materials with properties that include conducting, semiconducting, superconducting, insulating, dielectric, magnetic, optoelectronic, piezoelectric, ferroelectric and thermoelectric. Indexed/Abstracted： Web of Science SCIE Scopus CAS INSPEC Portico