3d printing with graphene & ceramics: michael petch keynote paris, may 2016
TRANSCRIPT
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3D Printing with Novel Materials Production, Processing & Performance
Michael Petch – Black Dog Consulting
Inside 3D Printing Conference, Paris. 26th May 2016
[email protected] @michaellpetch
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10 CERAMICS: FUTURE?
11 GRAPHENE: WHAT?
03 ABOUT ME
04 MATERIAL DISCOVERY .
05 LONG TERM STRATEGY
06 CERAMICS: WHAT?
07 CERAMICS: MATERIALS
14 GRAPHENE: PROCESSING
15 GRAPHENE: PERFORMANCE
16 GRAPHENE: FUTURE?
17 OTHER MATERIALS
agenda 3D PRINTING & NOVEL MATERIALS
08 CERAMICS: PROCESSING
09 CERAMICS: PERFORMANCE
12/13 GRAPHITE/GRAPHENE: PRODUCTION
18 QUESTIONS
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MICHAEL PETCH Author, analyst, & consultant.
Image Credit: Gyges 3D
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Material Discovery & Development
1886 Aluminium $1,200 / kg
2016 Aluminium
$2 / kg.
2015 US 100% reliant on
imports for 19 critical minerals
Image Credits: AP Photo, UT Library, Compound Chem, US Geological Survey.
Smartphones contain half elements in
periodic table. Av. Life = 3
years (Bakker, 2014)
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“Over the long term, actions to increase resiliency may include the development of new methods of extraction, processing, and manufacturing that promote the efficient use of materials; increased recovery of materials from waste and scrap; and research and development of alternative materials and new product designs to reduce the demand for limited materials.”
Testimony to Senate Energy and Natural Resources Committee on May 12, 2015 by Richard Silberglitt, RAND
6 Ceramics: What?
Image Credits: Petr Novak Wikipedia , Engineering Civil, Empa
50% of everything made this year will be made from ceramics (Purnell, 2013)
Post-hard machining incurs up to 80% of the overall manufacturing costs of a ceramic product (Travitzky et al., 2014)
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Ceramics: Materials Ceramics vs Fine / Advanced Ceramics
Chart Data Source: Fine Ceramics World
Ceramic paste Ceramic powder Liquid binder (for binder jet) Photo-curing ceramic composite resin Preceramic paper
Materials for AM
SiC preceramic paper for LOM (Travizky, 2014)
UV curable monomers & UV photo initiator.
(Schaedler et al., 2016)
8 Ceramics: Processing
Image Credits: Laurens van Lieshout, Sandia National Laboratories/Randy Montoya, Heraclitus by Hendrick ter Brugghen, HRL Laboratories LLC, Schaedler et al., 2016.
AM techniques for working with ceramics.
1 Foil supply. 2 Heated roller. 3 Laser beam. 4. Scanning prism. 5 Laser unit. 6 Layers. 7 Moving platform. 8 Waste.
Laminated Object Manufacturing with preceramic paper
Robocasting with hydrogels & ceramic
slurries
UV Stereolithography with silicon oxycarbide
9 Ceramics: Performance
Image Credits: Özkol et al., 2012, Feilden et al., 2016, Schaedler et al., 2016, HRL Laboratories/Dan Little, General Electric GE9X , Joannopoulos et al., 2011.
Biomedical, aerospace, electronics & semiconductors. Complex geometry, low porosity, high strength & thermal resistance.
10 Ceramics: Future?
Image Credits: NASA, Carpenter, J.
11 Graphene: What?
Image Credits: Nobel Museum, Alexander AIUS, Tian et al. 2006, Novoselov & Geim: Roadmap for Graphene 2015.
A two-dimensional, atomic scale, monolayer, polyaromatic hydrocarbon. A single sheet of graphite.
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Graphite: Production Graphite demand to increase by 200% within 4 years.*
Image Credit: USGS, 2016, *Benchmark Mineral Intelligence
China: 72% installed capacity worldwide, 55% total flake graphite production.
3 ton natural flake graphite
= 1 ton spheroidal graphite
800 million tons =
World recoverable graphite
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Graphene: Production Graphite must be intercalated to render it susceptible to exfoliation.
Image Credit: Garg et al., 2014, Ben Mills
Sulfuric acid
Potassium permangate
Sodium nitrate
Potassium persulfate
Phosphorus pentoxide
1. Oxidation of graphite Brodie Method (1859) Hummers Method (1958) Modified Hummers (Kovtyukhova, 1999 & Tour, 2010)
2. Exfoliation 3. Reduction 4. Dispersal or Nanocomposite
14 Graphene: Processing
Image Credits: Griffiths, 2015, Dul et al. 2016, Jabari & Toyserkani, 2015.
AM & fabrication techniques for working with graphene.
“Gbot” UV curable 3D printable graphene ink
Extrusion with thermoplastic polymer nanocomposite (PNG)
Aerosol jet printing for graphene interconnects
15 Graphene: Performance
Image Credits: Zhu et al., 2015, Zhu et al., 2016, Hersam et al., 2015
Super capacitors, electronic & biomedical applications
16 Graphene: Future?
Image Credits: Nokia, Volvo, Columbia University, Pacific Water
17 Other Materials & Applications
Image Credits: Molybdenum, John Rogers, Wuhan National Laboratory for Optoelectronics, Drexler & Pamlin, 2013
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