Multi-Material Additive Manufacturing Opens Doors to In-House Prototyping

This week, a team of University of Missouri researchers published a study in the scientific journal Nature Communications that introduced a new method of 3D printing complex multi-material devices. This method leverages lasers and direct ink writing to enable a new level of flexibility for new product designers. Here’s what the researchers discovered and how it could revolutionize multiple industries in the coming years.

Major Problems with Multi-Material Additive Manufacturing

Manufacturing items that require the use of multiple different materials and processes has been one of the largest tasks that engineers have attempted to tackle since the earliest days of the Industrial Revolution. Today, the task is still time-consuming, expensive, and requires the use of multiple third parties.

Source – University of Missouri

Currently, the 3D printing industry is in the midst of a revolution. There are new techniques, methods, and materials that have improved the usability of these devices. However, these units are restricted in their material crossover and capabilities. The method introduced by researchers has the potential to streamline this task down to a single printer that is capable of printing plastics, metals, and semiconductors with accuracy.

Wasteful

Manufacturing complex multi-material products is extremely wasteful. If it’s done in-house, the processes have to be adjusted to meet the restraints of the location and funding. If the task is outsourced, there are additional costs associated with shipping the product to different manufacturers. The all-in-one 3D printing process proposed by the researchers would eliminate these concerns and provide a streamlined in-house method that could maximize efficiency.

Multi-Material Additive Manufacturing Study

The study introduces the freeform multi-material assembly process (FMAP). FMAP integrates a single machine to accomplish tasks that used to take multiple manufacturers. To accomplish the task, the printer uses fused filament fabrication (FFF), direct ink writing (DIW), and freeform laser induction (FLI), which enhances printing capabilities across materials.

According to the report, a purpose-built 3-nozzle 3D printer was constructed. The first nozzle was tasked with adding the filament. The second nozzle used freeform laser induction (FLI) to alter the material in open space. The final nozzle then introduced additives and any other functional materials needed to complete the item.

Test

The testing included using a polycarbonate variant to create complex devices. The units had functional materials that were predesigned and applied autonomously with high accuracy. In total, the researchers created a functioning UV sensor, a 3D magnetic encoder, a crossbar LED circuit, a tension sensor for multifunctional springs, and capacitive sensors. Their final task was the most difficult: an integrated microfluidic reactor with a built-in Joule heater, which is typically used for nanomaterial synthesis.

Researchers

The study was conducted at the University of Missouri. It was led by Doctoral student Bujingda Zheng. Additionally, Jian “Javen” Lin, an associate professor of mechanical and aerospace engineering, co-led the project. The funding for the research came from the National Science Foundation (NSF) Advanced Manufacturing program and the NSF I-Corps.

Inspirations

When interviewed about their project, the researchers responded by saying they took inspiration from nature. They explained that nature does not waste. It evolves to integrate every cell with a purpose and structure. Their goal is to apply this level of efficiency to today’s manufacturing processes, reducing waste while driving innovation.

Benefits of Multi-Material Additive Manufacturing

There are several benefits that the researchers’ new method of 3D printing brings to the table. For one, it reduces the costs of creating products. A single machine that can manufacture multi-material, multi-layered sensors, circuit boards, and textiles could revolutionize the industry. When you add the ability to integrate electronic components, you open the door for next-generation engineers to create freely.

Better Prototyping

These all-in-one printing devices will enable engineers to create and test prototypes much faster than compared to today’s methods. A 3D-printed device could be made in hours or days rather than weeks typically needed to prototype new devices currently. In the future, designers will be able to create without worrying about prototyping processes.

The device would enhance in-house R&D capabilities for many businesses globally. It reduces fabrication times, costs, and improves the deployment of new products to the market. As such, there is a lot of attention on the researchers’ endeavors.

Multi-Material Additive Manufacturing Applications

There are many applications for integrated 3D-printed devices. These units are easier to create. They leverage automated systems that can integrate AI to improve quality control. Here are a few promising applications for this technology that you could see come to the market in the coming years.

Hi-end Natural Sensors

Monitoring nature is a precise science that requires the ability to continually gather data without interrupting the ecosystem. To accomplish this task, researchers have created clever methods of hiding their sensing equipment. This new method of 3D printing would enable them to produce natural-looking objects that blend perfectly with the environment while providing real-time data.

Smarter Machines

Another application is making machines that can feel. Integrating temperature and pressure sensors into devices would provide another layer of perception to these units. In the future, robots could be created smaller and more agile using this tech.

Wearable Sensors

The wearables market is on the rise. There are major investments across the fitness, military, and healthcare sectors. Wearables have found a home in helping people recover from health concerns. They provide real-time monitoring and have become very popular. The integration of 3D printing functionality would make these devices smaller and more comfortable. As such, they could begin to be made for extended or even permanent wear.

The wearable market is a fast-growing sector, with reports predicting it to hit $186.48B this year. Additionally, analysts predict the industry to grow at a CAGR of 17.60%, reaching $493.26B by 2029. 3D Printing these devices could make them more accessible and cheaper to manufacture, driving adoption further.

Robots

Robotics has the most to gain from these innovations. 3D printed circuits and complex devices could reduce weight in robots. Any weight reduction results in added power and battery life for these devices. As such, tomorrow’s robots will be lighter, faster, smarter, and more agile than their predecessors. Additionally, they could integrate 3D printers to conduct self-repairs in remote locations.

Companies that could Gain from these Findings

The 3D printing industry continues to expand with innovations driving the market in several directions. Notably, the 3D-printed microchip industry is one of the fastest-growing and most successful. Here are a few companies that could integrate new 3D printing methods to improve their products and efficiency.

1. Qualcomm Incorporated

QUALCOMM Incorporated (QCOM +1.93%)

Qualcomm Incorporated has been a pioneer in the telecommunications and tech market since it entered service in 1985. The manufacturer made a name for itself creating advanced telecommunication equipment and semiconductors. Its most famous offerings are the CDMA/WCDMA and Snapdragon processors.

Qualcomm remains a dominant force in the market. This San Diego-based company secured $35.82B in profit in 2023. The company is seen as a strong “hold” due to its market positioning and innovative products set for release. Integrating the inclusive 3D printing process for their popular chipsets would drive revenue up and reduce waste.

2. Monolithic Power Systems

Monolithic Power Systems, Inc. (MPWR +2%)

Monolithic Power Systems, Inc. is another publicly traded semiconductor manufacturer that is considered a pioneer in the market. The company is based out of Washington, US, and was founded in 1997. Today it has its products in use across various industries including, automotive, industrial, communications, computing, and storage.

Monolithic Power Systems Inc. reported a revenue of $1.82B in 2023. It’s worth noting that demand for semiconductors is on the rise, which has led many to consider this manufacturer a smart addition to their portfolio. Integrating the new 3D printing process could enhance their business model further, driving innovation and profits.

Future of Multi-Material Additive Manufacturing

The future of the 3D printing market is bright. These devices are more popular than ever and have been created to print everything from metals to medicine. Here are a couple of other cool 3D printing projects that are worth noting.

Space Printing

It’s one thing to print a device on Earth. However, it’s a completely different task when in a low-gravity situation. Researchers recently tested a new 3D printing process designed to enable these units to operate in space. Their study opens the door for longer space travel and a future where sustainability is a prime concern.

Medicine Printing

Future medications will be 3D printed at your local pharmacy. There have been recent breakthroughs in the quality control mechanisms of these devices. Soon, 3D-printed medicines will be more accurate and precise than human-mixed options, opening the door for more efficient distribution and personalized care.

Multi-Material Additive Manufacturing – Getting Closer to Sci-fi

This development brings the industry closer to sci-fi with the ability to print complete electronic functioning devices that integrate metals, plastics, and electronics. This capability will provide a new level of ingenuity to the market and empower creators to innovate freely. As such, you can expect to see more coverage of this device as researchers continue to explore its capabilities.

Learn about other cool manufacturing projects now.