University of Missouri researchers have developed a groundbreaking technique called the Freeform Multi-material Assembly Process, which allows for the creation of complex devices using multiple materials with a single machine. This method, outlined in a recent publication in Nature Communications, enables the fabrication of multi-material, multi-layered sensors, circuit boards, and textiles with electronic components. By using this innovative approach, sensors can be embedded within structures to allow for the monitoring of environmental conditions such as temperature and pressure, with potential applications in wearable devices for monitoring vital signs.
The technology developed by the Mizzou team involves the use of a machine equipped with three different nozzles for adding ink-like material, using a laser to carve shapes and materials, and incorporating additional functional materials to enhance the product’s capabilities. The process begins with the creation of a basic structure using regular 3D printing filament, which is then modified using a laser to convert some parts into laser-induced graphene, a special material that is placed precisely where needed. Finally, additional materials are added to improve the functional abilities of the final product. This revolutionary approach addresses the limitations of existing techniques in terms of versatility of materials and precision in placing smaller components within larger 3D structures.
Funded by the National Science Foundation’s Advanced Manufacturing program, the Mizzou team is also exploring commercialization opportunities with support from the NSF I-Corps program. The researchers believe that their technology has the potential to significantly impact the fabrication and manufacturing processes of various products. By shortening fabrication time for device prototyping and allowing companies to create prototypes in-house, this technology could transform the way products are developed and manufactured, benefiting both researchers and businesses. The potential applications of this new technique range from wearable sensors to customizable robots and medical devices, opening up opportunities for entirely new markets.
Lead author of the study, Bujingda Zheng, a doctoral student in mechanical engineering at Mizzou, expressed excitement about the design and the opportunities presented by this novel process. Zheng highlighted the importance of innovation in designing new products without the constraints of prototyping limitations. Associate Professor Jian “Javen” Lin emphasized the broad impacts this technology could have on various industries, with the potential to revolutionize wearable sensors, customizable robots, medical devices, and more. By simplifying the manufacturing process of multi-layered structures like printed circuit boards, the new technique offers a more efficient and environmentally friendly alternative to traditional methods.
The innovative approach developed by the Mizzou team is not only more efficient and environmentally friendly than current manufacturing processes, but it is also inspired by natural systems. Drawing inspiration from the structure-function relationships observed in nature, such as electrical eels with bones and muscles that enable movement and specialized cells for discharging electric shocks, the researchers have created a method for fabricating 3D structures with multi-functional applications. This nature-inspired approach offers a new perspective on material design and fabrication techniques, elevating the possibilities for creating innovative products across various industries. As the first of its kind, the Freeform Multi-material Assembly Process unlocks new possibilities and demonstrates the potential for transforming the way products are fabricated and manufactured.