Direct Digital Fabrication: Integration of Advanced Manufacturing Processes
Lead Research Organisation:
Loughborough University
Department Name: Sch of Mechanical and Manufacturing Eng
Abstract
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Organisations
Publications
Ta D
(2015)
Nanosecond laser textured superhydrophobic metallic surfaces and their chemical sensing applications
in Applied Surface Science
Ta V
(2016)
Laser textured surface gradients
in Applied Surface Science
Ta V
(2016)
Laser textured superhydrophobic surfaces and their applications for homogeneous spot deposition
in Applied Surface Science
Li J
(2016)
Hybrid additive manufacturing of 3D electronic systems
in Journal of Micromechanics and Microengineering
Stringer J
(2016)
Integration of additive manufacturing and inkjet printed electronics: a potential route to parts with embedded multifunctionality
in Manufacturing Review
| Description | The template driven nature of traditional electronics manufacturing requires volume production to achieve economically viability. This results in long pre-production timescales, a lack of versatility and customisation. Conversely, Additive Manufacturing (AM), commonly termed 3D printing, is a family of processes that produce parts directly from a digital model without the need for templates or moulds and can rapidly produce unique and highly complex parts. However, inherently, each AM process alone has resolution and material constraints. In relation to electronics manufacturing a wide range of materials including conductors and dielectrics must be deposited in order to generate complex circuitry and interconnects. In order to enable truly functional products using 3D printing, the integration of multiple digitally driven processes is seen as the solution to many of the current limitations arising from standalone AM techniques. During this project the researchers at University of Loughborough (now at the University of Leeds) have developed a process capable of digitally fabricating fully functioning electronics using a unique combination of AM technologies. This has been achieved by interleaving bottom-up Stereolithography (SL) with direct writing (DW) of conductor materials alongside mid-process development, dispensing of interconnects, component placement and thermal curing stages. The resulting process enables the low-temperature production of bespoke three-dimensional, fully packaged and assembled multi-layer embedded electronic circuitry. This new paradigm in manufacturing supports rapid iterative product development, mass customisation of electronics for a specific application and allows the generation of more dimensionally complex products with increased functionality. |
| Exploitation Route | This flexible and reconfigurable manufacturing process chain could be applied to a wide range of applications to generate multimaterial functioning devices. |
| Sectors | Electronics,Manufacturing, including Industrial Biotechology |
| Description | This project has seen the various researchers career flourish as a result of the experience and mentoring from working within a highly multi-disciplinary and multi-institutional research grant. For example Dr. Ji Li the PDRA from Loughborough University on the project secured an academic posting in China, Dr. Tom Wasley is a lead engineer at the Manufacturing Technology Centre Catapult and Dr. Maria Mirgkizoudi is now Head of Technology & Packaging Engineering for Airbus Defense. The Industrial partners have also benefited from this project from the fostering of new collaborations, developing new application areas, additional equipment sales and improved product development capability. The approach taken by Dr. Kay and team example one of the first Hybrid Additive Manufacturing approaches to produce multi-material functional structures. This background research alongside other EPSRC funded research was recently validated as internationally leading by peer review through the award of the A Platform for Hybrid Manufacturing Process research (EP/P027687/1). |
| First Year Of Impact | 2015 |
| Sector | Electronics,Manufacturing, including Industrial Biotechology |
| Impact Types | Economic |
| Description | A Platform for Hybrid Manufacturing Process research |
| Amount | £1,675,629 (GBP) |
| Funding ID | EP/P027687/1 |
| Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
| Sector | Public |
| Country | United Kingdom |
| Start | 06/2017 |
| End | 06/2022 |
| Description | Additive Manufacturing and 3D printing workshop |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Industry/Business |
| Results and Impact | The International Microelectronics and Packaging Society (IMAPS) Workshop on Additive Manufacturing (printing) for packaging was hosted by Dr. Robert Kay at Loughborough University on the 22nd October 2015. This workshop brought together a range of individuals primarily from industry in order to introduce them to the current developments and activities in 3D printing applied to the field of electronics. The workshop was split into a morning session which educated these new individuals into the field of Additive Manufacturing and then in the afternoon covered the latest developments in academia and industry around 3D printing for electronics manufacturing. The research findings from two EPSRC projects was also showcased at this event (EP/L017415/1 & EP/L022133/1). Besides the networking benefits from this event the investigators on this grant were able to establish new collaborations with industry on existing and future research activities. The event also raised the awareness of many of the research activities in this field currently being conducted by UK Universities. |
| Year(s) Of Engagement Activity | 2015 |
| URL | https://imapsuk.wordpress.com/2015/09/08/additive-manufacturing-and-3d-printing-workshop-programme-a... |
| Description | Inspiring the next generation of students into Mechanical and Manufacturing Engineering. Smallpeice Trust event at University of Warwick for Year 12 Students, July 2017 |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Schools |
| Results and Impact | My aim was to deliver a talk that inspired students into engineering by me sharing my own personal experiences and research activities. The talk received many questions afterwards plus I received feedback by e-mail from some students thanking me for an enjoyable talk. |
| Year(s) Of Engagement Activity | 2017 |
| Description | Invited to the Additive Manufacturing BSI Committee |
| Form Of Engagement Activity | A formal working group, expert panel or dialogue |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Third sector organisations |
| Results and Impact | As a result of my work in developing new Additive Manufacturing processes including Photobioform I was invited to apply to stand on the British Standards Institute (BSI) Additve Manufacturing Technologies (AMT/8) committee. Our work also feeds into International standards including ISO and ASTM. |
| Year(s) Of Engagement Activity | 2021,2022 |
| URL | https://standardsdevelopment.bsigroup.com/committees/50226095#:~:text=Overview%3A%20Under%20the%20di... |
| Description | Presentation at the Solid Freeform Fabrication Symposium - Additive Manufacturing of High Resolution Embedded Electronic Systems |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Postgraduate students |
| Results and Impact | The presentation given at this event titled "Additive Manufacturing of High Resolution Embedded Electronic Systems" was well received and resulted in a host of new North American contacts and resulted in a number of requests for further information. |
| Year(s) Of Engagement Activity | 2016 |
| Description | School Of Mechanical Engineering Seminar, 9th November 2017 Hybrid Additive Manufacturing of 3D Electronic Systems |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | Local |
| Primary Audience | Professional Practitioners |
| Results and Impact | 30 individuals from the School of Mechanical Engineering Attended an Invited Colloquium where Dr. Robert Kay presented his portfollio of EPSRC funded research in the area of "Hybrid Additive Manufacturing of 3D Electronic Systems". This talk has sparked discussions to form new potential research collaborations in the field of Manufacturing Processes Research. |
| Year(s) Of Engagement Activity | 2017 |
| Description | The investigators, post-graduate researchers and PhD students from this project organised a 2. 5day off-site team development activity in Argyll, Scotland. |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Postgraduate students |
| Results and Impact | A facilitator was used to organise a range of activities off-campus around team development activities, research planning, creative thinking and blue sky research ideas generation. All project investigators and project researchers attended this event from the 5-7th April 2016 in Argyll Scotland. The researchers particular found the various sessions very useful for developing multidisciplinary research ideas. In addition, the team came up with some new concepts for developing into publications and research proposals as a result of this event. |
| Year(s) Of Engagement Activity | 2016 |