Abstract
Printing technology has been extensively investigated, with the majority of that investigation historically based upon applications to the two-dimensional printing industry. Recently, however, it has spread to numerous new application areas, including electronics packaging, optics, and additive manufacturing. Some of these applications, in fact, have literally taken the technology into a new dimension. The employment of printing technologies in the creation of three-dimensional products has quickly become an extremely promising manufacturing practice, both widely studied and increasingly widely used.
This chapter will summarize the printing achievements made in the additive manufacturing industry and in academia. The development of printing as a process to fabricate 3D parts is summarized, followed by a survey of commercial polymer printing machines. Both direct part printing and binder printing technologies are introduced. Direct printing refers to processes where all of the part material is dispensed from a print head, while binder printing refers to a broad class of processes where binder or other additive is printed onto a powder bed which forms the bulk of the part. Some of the technical challenges of printing are introduced; material development for printing polymers, metals, and ceramics is investigated in some detail. From the topic of pure printing technologies, we move to the three-dimensional binder printing process, where binder is printed into a powder bed to form a part.
References
Le HP (1998) Progress and trends in ink-jet printing technology. J Imaging Sci Technol 42(1):49–62
The rapid prototyping patent museum: basic technology patents. http://home.att.net/~rppat/museum/mus_2.htm. Accessed 19 March 2006
Wohlers T (2004) Wohlers Report 2004. Wohlers Associates, Fort Collins
Solidscape. T66 Benchtop: Product Description. http://www.solid-scape.com/t66.html. Accessed 31 July 2006
Polyjet technology – 3-dimensional printing applications. http://www.2objet.com. Accessed 19 March 2006
In-Vision 3D printer. http://www.cadem.com.tr/3dsystems/invision/index.html. Accessed 19 March 2006
Gao F, Sonin AA (1994) Precise deposition of molten microdrops: the physics of digital fabrication. Proc R Soc Lond A 444:533–554
Reis N, Seerden KAM, Derby B, Halloran JW, Evans JRG (1999) Direct inkjet deposition of ceramic green bodies: II – jet behaviour and deposit formation. Mater Res Soc Symp Proc 542:147–152
Feng W, Fuh J, Wong Y (2006) Development of a drop-on-demand micro dispensing system. Materials Science Forum 505–507 (January 2006):25–30
Tay B, Edirisinghe MJ (2001) Investigation of some phenomena occurring during continuous ink-jet printing of ceramics. J Mater Res 16(2):373–384
Derby B, Reis N (2003) Inkjet printing of highly loaded particulate suspensions. MRS Bull 28(11):815–818
Ainsley C, Reis N, Derby B (2002) Freeform fabrication by controlled droplet deposition of powder filled melts. J Mater Sci 37:3155–3161
Zhao X, Evans JRG, Edirisinghe MJ (2002) Direct ink-jet printing of vertical walls. J Am Ceram Soc 85(8):2113–2115
Wang T, Derby B (2005) Ink-jet printing and sintering of PZT. J Am Ceram Soc 88(8):2053–2058
Liu Q, Orme M (2001) High precision solder droplet printing technology and the state-of-the-art. J Mater Process Technol 115:271–283
Priest JW, Smith C, DuBois P (1997) Liquid metal jetting for printing metal parts. Solid Freeform Fabrication Symposium
Orme M (1993) A novel technique of rapid solidification net-form material synthesis. J Mater Eng Perform 2:399–405
Orme M, Huang C, Courter J (1996) Precision droplet-based manufacturing and material synthesis: fluid dynamics and thermal control issues. Atomization and Sprays 6:305–329
Yamaguchi K (2003) Generation of 3-dimensional microstructure by metal jet. Microsystem Technol 9:215–219
Yamaguchi K, Sakai K, Yamanka T, Hirayama T (2000) Generation of three-dimensional micro structure using metal jet. Precision Eng 24:2–8
Liu Q, Orme M (2001) On precision droplet-based net-form manufacturing technology. Proc I MECH E Part B – J Eng Manufacture 215:1333–1355
Cao W, Miyamoto Y (2006) Freeform fabrication of aluminum parts by direct deposition of molten aluminum. J Mater Process Technol 173:209–212
Furbank RJ, Morris JF (2004) An experimental study of particle effects on drop formation. Phys Fluids 16(5):1777–1790
Bechtel SE, Bogy DB, Talke FE (1981) Impact of a liquid drop against a flat surface. IBM J Res Dev 25(6):963–971
Pasandideh-Fard M, Qiao Y, Chandra S, Mostaghimi J (1996) Capillary effects during droplet impact on a solid surface. Phys Fluids 8(3):650–659
Thoroddsen ST, Sakakibara J (1998) Evolution of the fingering pattern of an impacting drop. Phys Fluids 10(6):1359–1374
Bhola R, Chandra S (1999) Parameters controlling solidification of molten wax droplets falling on a solid surface. J Mater Sci 34:4883–4894
Attinger D, Zhao Z, Poulikakos D (2000) An experimental study of molten microdroplet surface deposition and solidification: transient behavior and wetting angle dynamics. J Heat Transf 122:544–556
Bussman M, Chandra S, Mostaghimi J (2000) Modeling the splash of a droplet impacting a solid surface. Phys Fluids 12(12):3121–3132
Schiaffino S, Sonin AA (1997) Molten droplet deposition and solidification at low Weber numbers. Phys Fluids 9(11):3172–3187
Orme M, Huang C (1997) Phase change manipulation for droplet-based solid freeform fabrication. J Heat Transf 119:818–823
Sanders R, Forsyth L, Philbrook K (1996) 3-D Model maker. US Patent No. 5506706
Thayer J, Almquist T, Merot C, Bedal B, Leyden R, Denison K, Stockwell J, Caruso A, Lockard M (2001) Selective deposition modeling system and method. US Patent No. 6305769
Gothait H (2005) System and method for three-dimensional model printing. US Patent No. 6850334
Gothait H (2001) Apparatus and method for three-dimensional model printing. US Patent No. 6259962
Bedal B, Bui V (2002) Method and apparatus for controlling the drop volume in a selective deposition modeling environment. US Patent No. 6347257
Tay B, Evans JRG, Edirisinghe MJ (2003) Solid freeform fabrication of ceramics. Int Mater Rev 48(6):341–370
De Gans BJ, Duineveld PC, Schubert US (2004) Inkjet printing of polymers: state of the art and future developments. Adv Mater 16(3):203–213
MicroFab technote 99-01: Background on ink-jet technology. http://www.microfab.com/equipment/technotes/technote99-01.pdf. Accessed 19 March 2006
Teng W, Edirisinghe MJ (1998) Development of continuous direct ink jet printing of ceramics. Br Ceram Trans 97(4):169–173
Blazdell PF, Evans JRG, Edirisinghe MJ, Shaw P, Binstead M (1995) The computer aided manufacture of ceramics using multilayer jet printing. J Mater Sci Lett 54:1562–1565
Blazdell PF (2003) Solid free-forming of ceramics using a continuous jet printer. J Mater Process Technol 137:49–54
Tseng AA, Lee MH, Zhao B (2001) Design and operation of a droplet deposition system for freeform fabrication of metal parts. J Eng Mater Technol 123:74–84
Basaran OA (2002) Small-scale free surface flows with breakup: drop formation and emerging applications. AIChE J 48(9):1842–1848
Sirringhaus H, Kawase T, Friend RH, Shimoda T, Inbasekaran M, Wu W, Woo EP (2000) High-resolution inkjet printing of all-polymer transistor circuits. Science 290:2123–2126
Shimoda T, Morii K, Seki S, Kiguchi H (2003) Inkjet printing of light-emitting polymer displays. MRS Bull 28:821–827
Lee E (2002) Microdrop generation. CRC Press, Boca Raton
Percin G, Khuri-Yakub BT (2002) Piezoelectrically actuated flextensional micromachined ultrasound droplet ejectors. IEEE Trans Ultrason Ferroelectr Freq Control 49(6):756–766
Elrod SA, Hadimioglu B, Khuri-Yakub BT, Rawson EG, Richley E, Quate CF (1989) Nozzleless droplet formation with focused acoustic beams. J Appl Phys 65(9):3441–3447
Meacham JM, Ejimofor C, Kumar S, Degertekin FL, Fedorov AG (2004) Micromachined ultrasonic droplet generator based on a liquid horn structure. Rev Sci Instrum 75(5):1347–1352
Meacham JM, Varady M, Degertekin FL, Fedorov AG (2005) Droplet formation and ejection from a micromachined ultrasonic droplet generator: visualization and scaling. Phys Fluids 17:100605
Margolin L (2006) Ultrasonic droplet generation jetting technology for additive manufacturing: an initial investigation. MS Thesis, Georgia Institute of Technology
Fukumoto H, Aizawa J, Nakagawa H, Narumiya H (2000) Printing with ink mist ejected by ultrasonic waves. J Imaging Sci Technol 44(5):398–405
Sweet R (1964) High-frequency oscillography with electrostatically deflected ink jets. SEL-64-004, SELTR17221. Stanford Electronics Laboratories, Stanford, California
Munson B, Young D, Okiishi T (1998) Fundamentals of fluid mechanics, 3rd edn. Wiley, New York
MicroFab Technologies. MicroFab technote 99-02: fluid properties effects on ink-jet device performance. http://www.microfab.com/equipment/technotes.html
De Gans BJ, Kazancioglu E, Meyer W, Schubert US (2004) Ink-jet printing polymers and polymer libraries using micropipettes. Macromol Rapid Commun 25:292–296
Paton A, Kruse J (1995) Reduced nozzle viscous impedance. US Patent No. 5463416.
Leyden R, Hull W (1999) Method for selective deposition modeling. US Patent No. 5855836
Orme M, Courter J, Liu Q, Huang C, Smith R (2000) Electrostatic charging and deflection of nonconventional droplet streams formed from capillary stream breakup. Phys Fluids 12(9):2224–2235
Zhao X, Evans JRG, Edirisinghe MJ, Song JH (2001) Ceramic freeforming using an advanced multinozzle ink-jet printer. J Mater Synth Process 9(6):319–327
Xu P, Ruatta S, Schmidt K, Doan V (2004) Phase change support material composition. US Patent No. 66
Schmidt K (2005) Selective deposition modeling with curable phase change materials. US Patent No. 6841116
Sachs EM, Cima MJ, Williams P, Brancazio D, Cornie J (1992) Three-dimensional printing: rapid tooling and prototypes directly from a CAD model. J Eng Ind 114:481–488
Ex One, www.exone.com
Yoo J, Cima MJ, Khanuja S, Sachs EM (1993) Structural ceramic components by 3D printing. Solid freeform fabrication symposium, Austin, TX
Uhland S, Holman RK, Morissette S, Cima MJ, Sachs EM (2001) Strength of green ceramics with low binder content. J Am Ceram Soc 84(12):2809–2818
Cima MJ, Lauder A, Khanuja S, Sachs E (1992) Microstructural elements of components derived from 3D printing. Solid freeform fabrication symposium, Austin, TX
Grau J, Moon J, Uhland S, Cima MJ, Sachs E (1997) High green density ceramic components fabricated by the slurry-based 3DP process. Solid freeform fabrication symposium, Austin, TX
Williams CB, Rosen DW (2007) Cellular materials manufactured via 3D printing of metal oxide powders. Solid freeform fabrication symposium, Austin, TX, 6–8 Aug 2007
Williams CB (2008) Design and development of a layer-based additive manufacturing process for the realization of metal parts of designed mesostructure. Ph.D. Dissertation, Georgia Institute of Technology
Wohlers T (2006) Wohlers Report 2006. Wohlers Associates, Fort Collins, CO
Rapid prototyping: Let it grow. http://deskeng.com/articles/03/may/resourceguide/chart.pdf. Accessed 31 July 2006
Turkcadcam.net. http://www.turkcadcam.net/rapor/otoinsa/tek-harc-yigma-puskurterek.html. Accessed 31 July 2006
Desktop Engineering Magazine. Three printers: Same parts, different results. http://www.deskeng.com/Articles/Hardware-Review/Three-Printers:-Same-Parts,-Different-Results-20051216783.html. Accessed 31 July 2006
Engineer Live. 3D printing reaches out to the desktop and workshops of engineers and designers. http://www.engineerlive.com/homepage/features/14943/3d-printing-reaches-out-to-the-desktops-and-workshops-of-engineers-and-designers.thtml. Accessed 22 July 2006
Author information
Authors and Affiliations
Rights and permissions
Copyright information
© 2010 Springer Science+Business Media, LLC
About this chapter
Cite this chapter
Gibson, I., Rosen, D., Stucker, B. (2010). Printing Processes. In: Additive Manufacturing Technologies. Springer, Boston, MA. https://doi.org/10.1007/978-1-4419-1120-9_7
Download citation
DOI: https://doi.org/10.1007/978-1-4419-1120-9_7
Publisher Name: Springer, Boston, MA
Print ISBN: 978-1-4419-1119-3
Online ISBN: 978-1-4419-1120-9
eBook Packages: EngineeringEngineering (R0)