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Drying-oriented resolution optimization for multi-material additive manufacturing: A case study on coffee-ring effect
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DOI：10.1016/j.addma.2024.104609.png)
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Abstract
En 中文
While ink-based printing methods have been explored for creating novel materials and structures, the underlying impact of ink drying on printed materials, especially in the context of multi-axis, multi-material additive manufacturing (AM), is not well understood. Here, we investigate how different drying shapes affect the printing performance (e.g., composition, printing offset) using additive manufacturing of gradient materials as a case study. Different drying scenarios of coffee-ring effects are identified using shape functions, and their resulting influences on the uniformity and control of compositional gradients are showcased. While ideal deposition aims for continuously gradient materials, we observe that uneven ink drying poses a non-negligible effect on the composition of printed gradients. This has led to a required minimal offset (i.e. printing resolution in the AM process) for maintaining deposition gradient stability. This study presents a mathematical model to explain how the cross-sectional shape of a droplet, printing gradient resolution, and material gradient stability are related, predicting whether a uniform gradient will form based on the droplet's shape function after drying. Additionally, it introduces a drying-focused resolution optimization framework, capable of handling various droplet shapes, regardless of symmetry or concavity, to estimate the minimum printing resolution required for multi-material combinatorial fabrication.
Keywords:
Coffee-ring effect
Solution-based processing
Aerosol-jet printing
Manufacturing optimization