Materials and manufacturing are the critical enabler of our technological world. With new materials and advanced manufacturing, new opportunities for advanced application become possible. Additive manufacturing (AM), or three-dimensional (3D) printing, is a relatively new manufacturing process, which relies on building up of parts from raw material. It reduces manufacturing waste, is flexible in part output, and opens new final part form-factors/architectures to be accessible for advanced applications. Light-based AM is well established in its ability to fabricate complex 3D structures whose unique properties exceed or are unfound in natural materials, called metamaterials. These unique 3D structures and other benefits of light-based AM make it of increasing interest for fabrication of functional devices, energy storage, sensors, and actuators among others. However, the available materials compatible with light-based AM, and AM in general, is limited. Specific material and processing limitations, viscosity, light absorption, and their underlying chemistry exclude the vast majority of materials from use in light-based AM. The majority of usable materials are on acrylic, vinyl, and thiol-based organic polymers whereas most functional materials are inorganic and not directly compatible.This dissertation focuses on the development of new materials and processes to allow the light-based AM fabrication of functional materials. This includes graphene energy storage devices, patterned 3D deposition for freeform electronics of multiple materials (conductors, dielectric, magnetic), and high-temperature ceramics for lightweight structural electronics in extreme applications. This dissertation lays the foundation for integrating light-based AM methods to electronic device applications that incorporates conducting and dielectric materials in 3D. Further development can allow advanced antenna, bioelectronics, and structural electronics.

Additive Manufacturing: Materials, Processes, Quantifications and Applications is designed to explain the engineering aspects and physical principles of available AM technologies and their most relevant applications. It begins with a review of the recent developments in this technology and then progresses to a discussion of the criteria needed to successfully select an AM technology for the embodiment of a particular design, discussing material compatibility, interfaces issues and strength requirements. The book concludes with a review of the applications in various industries, including bio, energy, aerospace and electronics. This book will be a must read for those interested in a practical, comprehensive introduction to additive manufacturing, an area with tremendous potential for producing high-value, complex, individually customized parts. As 3D printing technology advances, both in hardware and software, together with reduced materials cost and complexity of creating 3D printed items, these applications are quickly expanding into the mass market. - Includes a discussion of the historical development and physical principles of current AM technologies - Exposes readers to the engineering principles for evaluating and quantifying AM technologies - Explores the uses of Additive Manufacturing in various industries, most notably aerospace, medical, energy and electronics

Projection micro-stereolithography (P SL) is a technique for micro-fabrication that can fabricate complex three-dimensional (3D) microstructures. However, this technique has been limited to printing low-volume structures with high resolution. My dissertation research introduces a large-area projection stereolithography (LAP SL) system that integrates scanning optics with the existing P SL to manufacture cm-scale objects with micro-scale architectures. This technique enables the fabrication of structures with features down to the sub-10 m scale and overall size up to hundreds of millimeters, which is particularly suitable for fabricating micro-architected metamaterials with large volumes that can be employed in a broad array of applications.The LAP SL system is capable of fabricating multi-scale features, making it possible to create lightweight structural materials with feature sizes from a few micrometers to hundreds of millimeters. Herein, we studied the process-structure-property relationships of a class of high-temperature ceramics via LaP SL. This study, for the first time, achieves high-resolution printing of high-temperature ceramics, with accurate three-dimensional feature sizes on the scale of a few micrometers, opening new opportunities for high-temperature material and device manufacturing. We discovered the size-dependent mechanical properties of high-temperature ceramics and their failure properties corresponding to various feature sizes. Furthermore, the LAP SL system is capable of fabricating metamaterials containing millions of unit cells, providing a unique experimental platform to study the fracture and damage tolerance of metamaterials. We additively manufactured stretch-dominated architected metamaterials with pre-defined embedded crack, where the size of the unit cells becomes sufficiently small compared to the flaw dimensions. Via combined experimental, X-ray tomography and numerical calculations, we have elucidated the emergence of fracture toughness as a material property in architected metamaterials, which is found to be a property largely influenced by the elastic instabilities of struts members and T-stress, A design map based on a 2-parameter fracture model was developed to guide the design of failure modes in micro-architected metamaterials. Beyond structural materials, my research then extends to the design and additive manufacturing of multi-functional materials and assembly-free devices for directional sensing, underwater transducers and meso-scale robotic systems. Using piezoelectric materials as an example, we demonstrated the process-structure-property relationships of additive manufacturing of multi-functional materials and energy transduction devices. A novel micro-stereolithography system integrated with the blade-casting process was developed and employed to print piezoelectric particles with surface functionalization. These as-printed piezo-active materials can be rationally designed to achieve programmable voltage-strain responses, going beyond the limitations of the intrinsic crystalline structures. The design strategy can be applied to create the next generation of intelligent infrastructure, able to perform a variety of structural and functional tasks, including simultaneous impact absorption and monitoring, three-dimensional pressure mapping and directionality detection. This study demonstrated the ease of implementation and utility of the piezoelectric metamaterials in underwater applications. Underwater transducers consisting of rationally designed metamaterials to accommodate diverse frequency ranges were developed. Through tuning geometry of the micro-architectures, the working range of the underwater transducers can vary from 10kHZ to 4MHz. With this broad frequency range, we developed hydrophones with arbitrary directivity patterns and ultrasonic array with high sensitivity. This study showed the feasibility and applicability of these underwater transducers for noise elimination and underwater object detection. Additionally, leveraging these piezo-active micro-architectures, my research then focused on additive manufacturable piezoelectric actuation metamaterials, with programmable deformation modes, including twisting, bending, shearing and axial strain under uniform electric fields. As a consequence of freeform design and fabrication, different types of metamaterial blocks and actuation modes can be combined into a single-piece material block and construct multiple degree-of-freedom modular actuation elements. The stackable, modular actuation elements allow the generation of complex coupled or decoupled motion without any transmission systems, which increases the energy efficiency of robotic systems generated by the piezoelectric metamaterials.

ADDITIVE MANUFACTURING With NOVEL MATERIALS The book explores practically the latest advancements and techniques in 3D and 4D printing using innovative and unconventional materials. This book comprehensively provides insights into various additive manufacturing processes, novel materials, and their properties, as well as the basic knowledge of AM process parameters, post-processing techniques, and their applications. It also explores the fundamental concepts and recent advancements in the development of novel materials for several applications, with special emphasis on platforms like AM techniques for polymers, ceramics, metallic materials, composites, nanomaterials, hydrogels, etc. Specific topics like environmental aspects of 3D printing and advanced 4D printing are also introduced. The technological aspects of AM are discussed in a concise and understandable way, with extensive illustrations. Also covered are the challenges and opportunities that arise from 3D printing with these materials. Audience The book will benefit researchers and industry engineers who work in additive manufacturing, mechanical engineering, 3D/4D printing, and materials science.

Additive Manufacturing Materials and Technologies discusses the recent developments and future possibilities in additive manufacturing. The book focuses on advanced technologies and materials, with chapters centered on shape memory materials, alloys and metals, polymers, ceramics, thermosets, biomaterials, and composites. Fiber-reinforced materials are covered as well, as are the life cycle and performance criteria of 3D printed materials. Other chapters look at the various applications of these materials and processing techniques, covering their use in the aerospace and automotive sectors, construction, bioengineering, and the pharmaceutical industry. Various additive manufacturing techniques such as electron beam melting, selective laser melting, laser sintered, fused deposition, and more are also studied. - Presents a comprehensive overview of recent advances in additive manufacturing technology and materials research and development - Outlines the processing methods, functionalization, mechanics, and applications of additive manufactured materials and technology - Summarizes lifecycles and performance parameters of 3D printed materials - Focuses on the types of shape memory materials and smart materials used in 3D printing in industrial applications and their applications

Highly comprehensive resource covering all key aspects of the current developments of additive manufacturing Additive Manufacturing Technology: Design, Optimization, and Modeling provides comprehensive and in-depth knowledge of the latest advances in various additive manufacturing technologies for polymeric materials, metals, multi-materials, functionally graded materials, and cell-laden bio-inks. It also details the application of numerical modeling in facilitating the design and optimization of materials, processes, and printed parts in additive manufacturing. The topics covered in this book include: Fundamentals and applications of 4D printing, 3D bioprinting of cell-laden bio-inks, and multi-material additive manufacturing Alloy design for metal additive manufacturing, mechanisms of metallurgical defect formation, and the mechanical properties of printed alloys Modified inherent strain method for the rapid prediction of residual stress and distortion within parts fabricated by additive manufacturing Modeling of the different stages in polymer and metal additive manufacturing processes, including powder spreading, melting, and thermal stress evolution By providing extensive coverage of highly relevant concepts and important topics in the field of additive manufacturing, this book highlights its essential role in Industry 4.0 and serves as a valuable resource for scientists, engineers, and students in materials science, engineering, and biomedicine.

Innovative Processes and Materials in Additive Manufacturing explains game-changing interdisciplinary applications of recent research breakthroughs in additive manufacturing technology. The number of research publications addressing additive manufacturing has soared in recent years as a range of disciplines explore the possibilities that this technology can provide. This book acts as a bridge between this high-level research and the large number of academics and practitioners looking to additive manufacturing for innovative solutions, providing them with practical and approachable information. Applications in aerospace, automotive, medical, construction, and food industries are addressed, featuring technical details that will help successful implementation. This unique book also provides broad coverage of the theory behind this emerging technology, including material development, as well as the technical details required for readers to investigate the novel applications of the involved methods for themselves. - Includes case studies from the aerospace, construction and medical industries - Features innovations in the integration of additive manufacturing processes with other manufacturing technologies - Identifies exciting routes for future research and application areas of additive manufacturing

This textbook covers in detail digitally-driven methods for adding materials together to form parts. A conceptual overview of additive manufacturing is given, beginning with the fundamentals so that readers can get up to speed quickly. Well-established and emerging applications such as rapid prototyping, micro-scale manufacturing, medical applications, aerospace manufacturing, rapid tooling and direct digital manufacturing are also discussed. This book provides a comprehensive overview of additive manufacturing technologies as well as relevant supporting technologies such as software systems, vacuum casting, investment casting, plating, infiltration and other systems. Reflects recent developments and trends and adheres to the ASTM, SI and other standards; Includes chapters on topics that span the entire AM value chain, including process selection, software, post-processing, industrial drivers for AM, and more; Provides a broad range of technical questions to ensure comprehensive understanding of the concepts covered.

This book provides knowledge about the process of creating and designing products based on an Industry 4.0 setting. The fundamentals of Additive Manufacturing, its many technologies, the process parameters, advantages, limitations, and recent developments are discussed. In addition, the most recent post-additive manufacturing process advancements, surface quality defects, and challenges are the primary topics that will be investigated in the book. Advances in Pre- and Post-Additive Manufacturing Processes: Innovations and Applications provides scientific and technological insights into the physical fundamentals of the machining and finishing processes in macro, micro, and nanoscales. It explores in a systematic way both conventional and unconventional material-shaping processes with various modes of hybridization concerning theory modelling and industrial potential. It focuses on the applications of Additive Manufacturing that are linked to pre-stage and post-stage processes and encompasses a broad spectrum of macro, micro, and nano-processes that are utilized in manufacturing activities. The book goes on to cover a wide range of reliable and economical fabrication of metallic parts with complicated geometries which are of considerable interest to the aerospace, medical, automotive, tooling, and consumer products industries. This reference title encapsulates the current trends of today’s material development and machining techniques for advanced composite materials, making it a one-stop resource for academic researchers and industrial firms while they are formulating strategic development strategies. It also serves as a reference book for students at all levels of education, from undergraduates to doctoral candidates.