3D printer that swallows plastics, metals, chips to build layered devices

Scientists have developed a new 3D printing machine that can easily produce complex devices.

Researchers at the University of Missouri have created this 3D printer that uses lasers to combine different materials to create complex and functional structures. Interestingly, this single machine can build multi-layer devices using a combination of materials such as plastics, metals and even semiconductors.

“This is the first time this type of process has been used, and it opens up new possibilities,” said Bujingda Zheng, a doctoral candidate in mechanical engineering at the University of Missouri and lead author of the study.

This new method paves the way for a new generation of devices and sensors, such as printed circuit boards and even fabrics with embedded electronics.

Printing process

Typically, building complex multi-layer devices such as printed circuit boards is a time-consuming process. It often involves multiple steps and the use of different machinery, and can be expensive. This can limit innovation and slow down the development of new products.

The new 3D printing machine is based on an innovative technique called the Freeform multi-material assembly process.

The new process is inspired by nature itself and is even environmentally friendly. Think of an electric eel, which has bones and muscles that enable it to move and specialized cells that produce electricity. This 3D printer works similarly.

“Everything in nature is composed of structural and functional materials,” Zheng said.

“For example, electric eels have bones and muscles that enable them to move. They also have specialized cells that can discharge up to 500 volts to deter predators. These biological observations have inspired researchers to develop new methods for producing 3D structures with multifunctional applications, but other emerging methods have limitations,” he explained.

This machine is like a 3D printing superhero. It has three nozzles: one builds the base structure using a regular 3D printing filament (e.g. polycarbonate). Specific shapes are then cut out using a laser nozzle and the parts are transformed into a special conductive material called laser-induced graphene. The final nozzle has specific features that ensure the full functioning of the final product.

The new machine has interesting applications

This new machine has various applications.

Interestingly, this machine can print sensors directly on rocks and shells. This will enable scientists to undertake environmental research such as monitoring ocean health and measuring water flow.

For everyday users, this could mean health monitoring devices that can be seamlessly incorporated into clothing and monitor everything from blood pressure to heart rate. This can eliminate the need for bulky devices.

The developers emphasize that this technology is a game changer in product development. Companies can now create prototypes on-site, drastically reducing prototyping time and speeding up the entire process.

“It opens up opportunities for completely new markets,” said Jian “Javen” Lin, an associate professor of mechanical and aerospace engineering at the University of Missouri.

“This will have a broad impact on wearable sensors, customizable robots, medical devices and more,” Lin concluded in a press release.

The results were published in the journal Nature communication.