Recent developments in selective laser processes for wearable devices

Recently,the increasing interest in wearable technology for personal healthcare and smart virtual/augmented reality applications has led to the development of facile fabrication methods.Lasers have long been used to develop original solutions to such challenging technological problems due to their remote,sterile,rapid,and site-selective processing of materials.In this review,recent developments in relevant laser processes are summarized under two separate categories.First,transformative approaches,such as for laser-induced graphene,are introduced.In addition to design optimization and the alteration of a native substrate,the latest advances under a transformative approach now enable more complex material compositions and multilayer device configurations through the simultaneous transformation of heterogeneous precursors,or the sequential addition of functional layers coupled with other electronic elements.In addition,the more conventional laser techniques,such as ablation,sintering,and synthesis,can still be used to enhance the functionality of an entire system through the expansion of applicable materials and the adoption of new mechanisms.Later,various wearable device components developed through the corresponding laser processes are discussed,with an emphasis on chemical/physical sensors and energy devices.In addition,special attention is given to applications that use multiple laser sources or processes,which lay the foundation for the all-laser fabrication of wearable devices.

Computational Analysis of Selective Laser Sintering of Inconel 625

A two-dimensional multi-physics finite element model is developed to simulate the Selective Laser Sintering(SLS)process using Inconel 625 powders.The validity of the developed model is first assessed by comparing its results with experimental data.Various factors such as phase transition,recoil pressure,surface tension,and theMarangoni force are considered.The study’s findings underscore that the morphology and thermal-fluid dynamics of the molten pool in the SLS process are predominantly shaped by the influence of the Marangoni force and recoil pressure acting on its surface.The recoil pressure at the front of the laser spot rises exponentially with temperature,making the liquid metal move downward,and creating a depression at the pool’s head.It also causes particles to splash from the pool’s rear edge.The study explores the influence of the backward Marangoni force,where hightemperature liquid flows from the front to the rear of the molten pool,creating a vortex and moving the pool in the rear.Process parameters like laser intensity,scan speed,and spot size were analyzed.The findings indicate that higher laser power lower scanning speed and laser beam spot size lead to increased width and depth of the molten pool.

Preparation of coated sand for selective laser sintering and optimization of baking process of sand moulds

A cold method was used to prepare coated sand for application in the selective laser sintering(SLS)process.Tensile strength,loss on ignition,gas evolution,and accuracy of the SLS samples were tested and analyzed,and the baking process was thoroughly investigated.Compared with coated sand prepared by the hot method,the cold method yields a more uniform and complete resin film on the sand's surface,resulting in enhanced tensile strength and accuracy.Additionally,the cold method requires a lower binder content to meet the same strength requirements,thereby minimizing gas evolution,reducing porosity defects,and ultimately improving casting quality.The coated sand samples prepared through the cold method exhibit superior accuracy,with a size error of within±0.4 mm.In contrast,the coated sand samples prepared by the hot method display a lower accuracy,with an average negative error of 2.1993 mm.The highest tensile strength could be attained by controlling the baking temperature within a suitable range(180-190°C),which can effectively reduce the generation of gas,thus contributing to improved overall performance.

Coating processes towards selective laser sintering of energetic material composites

This research aims to contribute to the safe methodology for additive manufacturing(AM)of energetic materials.Coating formulation processes were investigated and evaluated to find a suitable method that may enable selective laser sintering(SLS)as the safe method for fabrication of high explosive(HE)compositions.For safety and co nvenie nce reasons,the co ncept demonstration was conducted using inert explosive simulants with properties quasi-similar to the real HE.Coating processes for simulant RDXbased microparticles by means of PCL and 3,4,5-trimethoxybenzaldehyde(as TNT simulant)are reported.These processes were evaluated for uniformity of coating the HE inert simulant particles with binder materials to facilitate the SLS as the adequate binding and fabrication method.Suspension system and single emulsion methods gave required particle near spherical morphology,size and uniform coating.The suspension process appears to be suitable for the SLS of HE mocks and potential formulation methods for active HE composites.The density is estimated to be comparable with the current HE compositions and plastic bonded explosives(PBXs)such as C4 and PE4,produced from traditional methods.The formulation method developed and understanding of the science behind the processes paves the way toward safe SLS of the active HE compositions and may open avenues for further research and development of munitions of the future.

Synthesis of Polymer Nanocomposites for Selective Laser Sintering （SLS）

This paper presents initial development of polymer application. PNC materials containing a polyamide （PA） and nano to improve the mechanical properties. Commercial polyamide 6 nanocomposites （PNC） material for rapid manufacturing （RM） particles （5 wt%） were produced by solution blending with the aim （PA6） was dissolved in formic acid （HCO2H） together with two different types of nano particle materials： yttrium stabilised zirconia （YSZ） and Hectorite clay （Benton 166） and spray-dried to create powder, creating powder with particle sizes in the range of 10-40 μm. The materials were processed on a CO2 selective laser sintering （SLS） experimental machine. Mechanical properties of the PNCs were evaluated and the results were compared with the unfilled base polymer. Good dispersion of additives was achieved by solution blending, however the PA6 was degraded during the material preparation and spray drying process which resulted in the formation of porous structure and low strength. However the addition of 5 （wt%） nano particles in the PA6 has shown to increase strength by an average of 50-60%. Further work on powder preparation is required in order to fully realize these performance benefits.

Direct Slicing Based on Material Performance and Process Parameters for Selective Laser Sintering

Direct slicing from GAD models to generate sectional contours of the part to be sintered for Selective Laser Sintering （SLS） may overcome inherent disadvantages of using a Stereo Lithography （STL） format. In this paper, a direct slicing procedure is proposed for Selective Laser Sintering based on material performance and process parameters. Slicing thickness depends on the 3 D geometric model, material performance and process parameters. The relationship among material performance, process parameters and the largest slicing thickness is established using analysis of a sintering temperature field. A dynamic linked library is developed to realize direct slicing from a CAD model.

Morphology and Mechanical Properties of PS/Al_2O_3 Nanocomposites Based on Selective Laser Sintering

Selective laser sintering （SLS） is a new process to prepare the polystyrene （PS）/Al2O3 nanocomposites. In this paper, with different laser power and other processing parameters unchanged, the morphology, density and mechanical properties of the sintered specimens were investigated. It was found that nano-sized inorganic particles are uniformly located in the PS matrix and the maximum density of the sintered specimens with pure PS powder reaches 1.07 g/cm^3, higher than 1.04 g/cm^3 that of the sintered specimens with mixture powder. Due to strengthening and toughness of the nano-sized Al2O3 inorganic particles, the maximum notched impact strength and tensile strength of the sintered part mixed with nano-sized inorganic particles are improved greatly from 7.5 to 12.1 kJ/m^2 and from 6.5 to 31.2 MPa, respectively, under the same sintering condition.

Prediction of Sintering Strength for Selective Laser Sintering of Polystyrene Using Artificial Neural Network

In the present work,a study is made to investigate the effects of process parameters,namely,laser power,scanning speed,hatch spacing, layer thickness and powder temperature, on the tensile strength for selective laser sintering( SLS) of polystyrene( PS). Artificial neural network( ANN) methodology is employed to develop mathematical relationships between the process parameters and the output variable of the sintering strength. Experimental data are used to train and test the network. The present neural network model is applied to predicting the experimental outcome as a function of input parameters within a specified range. Predicted sintering strength using the trained back propagation( BP) network model showed quite a good agreement with measured ones. The results showed that the networks had high processing speed,the abilities of error-correcting and self-organizing. ANN models had favorable performance and proved to be an applicable tool for predicting sintering strength SLS of PS.

Selective laser sintering mechanism of polymer-coated molybdenum powder

A type of polymer-coated molybdenum powder used in selective laser sintering technology was prepared by coating polymer on molybdenum particles and frozen grinding techniques, with the maximum particle diameter of 71 μm. The laser sintering experiments of polymer-coated molybdenum powder were conducted by using the self-developed selective laser sintering machine (HLRP-350I). The method of microscopic analysis was used to investigate the dynamic laser sintering process of polymer-coated molybdenum powder. Based on the study, the laser sintering mechanisms of polymer-coated molybdenum powder were presented. It is found that the mechanism is viscous flow when the laser sintering temperature is between 100 ℃ and 160 ℃, which can be described by a two-sphere model; and the mechanism is melting /solidification when the temperature is above 160 ℃.

IGNITING SHS BY LASER AND ITS APPLICATION TO SELECTIVE LASER SINTERING OF METALLIC POWDER MATERIAL

How to directly fabricate metallic functional parts with selective laser sintering (SLS) process is a potential technique that scientists are researching. Existent problems during directly fabricating metal part by use of SLS are analyzed. For the sake of solving the problems, a new idea of adding self-propagating high-temperature synthesis (SHS) material into metallic powder material to form new type of SLS metallic powder material is put forward. This powder material can release controllable amount of heat during its interaction with the laser beam energy to reduce the requirement to laser power during directly sintering metallic part, to prolong the time of metallic liquid phase existing, and to improve the intensity and accuracy of SLS part. For this reason, SHS material′s interaction with the CO2 laser beam energy is researched, which proves that CO2 laser beam energy may instantly ignite SHS reaction. On the basis of the above-mentioned researches, the effect of sintering the metal powder material mixing SHS material with CO2 laser is also researched, which shows: there is an optimal blending ratio of various material in the new metallic powder material. Under the optimal blending ratio and SLS process parameters, this new metallic powder material can indeed release amount of heat and SHS reaction may be controlled within the laser sintering. This research result makes it possible that the metallic part is directly sintered with small CO2 laser (less than 50W), which may greatly reduce the volume, cost and running expenditure of SLS machine, be propitious to application.

Selective laser sintering of polymer-coated Al_2O_3/ZrO_2/TiC ceramic powder

A type of polymer-coated Al2O3/ZrO2/TiC ceramic powder was prepared. The laser sintering mechanism of polymer-coated Al2O3/ZrO2/TiC powder was investigated by studying the dynamic laser sintering process. It is found that the mechanism is viscous flow when the sintering temperature is between 80 ℃ and 120 ℃, and it is melting/solidification when the temperature is above 120 ℃. The process parameters of selective laser sintering were optimized by using ortho-design method. The results show that the optimal parameters include laser power of 14 W, scanning velocity of 1 400 mm/s, preheating temperature of 50 ℃ and powder depth of 0.15 mm. A two-step post-treatment process is adopted to improve the mechanical properties of laser sintered part, which includes polymer debinding and high temperature sintering. After vacuum sintering for 2 h at 1 650 ℃, the bending strength and fracture toughness of Al2O3/ZrO2/TiC ceramic part reach 358 MPa and 6.9 MPa·m1/2, respectively.

基于MSIWOA算法的SLS聚酰胺制件工艺参数优化

以聚酰胺粉末为实验材料,以力学性能为评价目标,研究了激光功率、扫描间距、摆放角度及他们两两交互作用对选择性激光烧结(SLS)制件抗拉强度的影响,通过扫描电镜观察断口形貌揭示了工艺参数对制件成型的影响机理,通过响应面设计得到了工艺参数与抗拉强度间的回归方程,分析了模型的有效性与准确性。以回归方程为目标函数,使用混合策略改进的鲸鱼优化(MSIWOA)算法进行SLS制件抗拉强度的优化,得到最优工艺参数,并与鲸鱼优化(WOA)算法的优化结果及实验验证结果进行比对。结果表明,MSIWOA算法对SLS聚酰胺制件工艺参数的优化具有较高的准确性和较好的可行性,可为SLS制件力学性能的提升提供技术方法。

Investigating on casting mold (or core) making with coated sand by the selected laser sintering

Using a special coated sand as the material of the selected laser sintering (SLS), the authors test and investigate the strength change of the test samples in terms of different sintering parameters (scanning speed, laser power, sintering thickness, and so on). The characteristics of coated sand hardening by laser beam are analyzed. The sintered mold (or core) for given casting is poured with molten metal.

Prediction and Analysis of Post-Treatment of Sustainable Walnut Shell/Co-PES Parts by Laser Sintering

In order to enhance the strength of sustainable walnut shell/Co-PES(WSPC)sintered parts,wax-filtrated posttreatment was carried out.The effects of treating fluid temperature,preheating time and immersion time on the bending strength of WSPC wax-filtrated parts were analyzed by single factor analysis method.To obtain an accurate model for predicting the bending strength of the WSPC wax-filtrated part,the experiments were involved by using Box-Behnken design(BBD).Main parameters,such as treating fluid temperature,preheating time and immersion time,and their interactive effects were analyzed through analysis of variance(ANOVA)and graphical contours.The results demonstrated that all parameters’direct effects were significant to bending strength of the WSPC wax-filtrated part.Its optimum value was 5.0 MPa when the treating fluid temperature of 70°C,preheating time of 50 min,and immersion time of 20 s.The predicted models effectively validated had good predicting accuracy.The WSPC wax-filtrated part using optimal processing parameters was processed by investment casting,and then the metal casting of dimensional stability and smooth surface was obtained.Investment casting was done using WSPC wax-filtrated parts under optimal process parameters and then metal parts with stable structure size and smooth surface can be obtained,which indicates that WSPC material can be used for investment casting.

骨组织工程支架的制备方法研究进展

背景:由于自体骨源的数量较少,且使用异体骨会产生免疫排斥、疾病扩散等危险,因而人造骨材料在当今的骨移植中起到了不可替代的作用。伴随着功能定制、生物相容性的要求和生物可降解材料的出现,已经出现了多样化的生物材料和多种制备方法。目的:概述目前应用于骨组织工程支架的制备方法,总结各种制备方法的优缺点、研究现状与进展。方法:使用计算机在中国知网、万方数据、PubMed及ScienceDirect数据库检索2008年1月至2023年8月关于骨组织工程支架方面的文献,以“Tissue engineering,Bone scaffold,Gas foaming,Cryotropic gelation,Additive manufacturing等”为英文检索词,以“组织工程,骨支架,气体发泡,低温凝胶,增材制造等”为中文检索词,排除无关和重复性研究,共保留80篇文献进行了总结归纳。结果与结论:①相较于传统支架的制备工艺,近年来新兴的增材制造和静电纺丝技术在用于组织工程的复杂结构如骨和软骨的生产中,表现出了巨大的潜力。②增材制造方法除了在速度、精度和使用的材料范围方面更具优势,还提供了制造高度复杂的几何形状和拓扑优化结构的可行性,实现精确调节和构造结构的高重复性。③静电纺丝是生产一系列纤维垫的最具适应性和前景的技术之一。通过静电纺丝产生的纳米纤维支架是与细胞质基质微观结构非常惊人地相似的生物材料。④目前在陶瓷材料上以羟基磷灰石和磷酸三钙应用性能较好,在高分子材料上目前材料种类多样,以生物相容性优良的材料应用较多。⑤因此,在骨组织工程支架材料的选择上应更好地了解它们的特性,避免复杂化,以生产更具增强功能的支架。然而,目前报告的绝大多数文献对临床的适用性都是探索性的,具体适合哪种疾病的治疗还有待检验。未来骨支架的发展需体现在这几个方面:与缺失骨相匹配的力学性能、降解速率可控、促进骨再生力强以及附有特定功能。

SLS成形件的收缩模型和翘曲模型

快速成形的精度是快速成形技术发展和扩大其应用领域的关键 ,工艺误差是影响成形精度的关键之一 ,而成形件收缩和翘曲对其工艺精度起决定性的作用。通过建立 SL S成形过程的收缩模型研究了 SLS加工中成形件的收缩形式以及收缩规律 ,同时研究了收缩的不均匀性所引起的翘曲 ,建立了成形件的翘曲模型。发现烧结收缩与烧结程度密切相关 ,翘曲量与烧结收缩率成正比 ,与零件线尺寸成正比。这些研究结果为克服 SL S加工收缩引起的误差和收缩补偿提供了依据 ,为减少翘曲变形提供了一种方法。

基于SLS烧结覆膜砂工艺参数对成型尺寸精度的影响规律

研究了激光功率P、扫描速度V和预热温度T对SLS烧结覆膜砂制件尺寸的影响。结果表明,随着激光功率增加,成型尺寸呈增大趋势;当激光功率为55.5 W时成型平面XY方向尺寸精度较高;成型尺寸随着扫描速度增加越来越小,当扫描速度为3 500 mm/s时成型平面XY尺寸精度较高;当预热温度小于60℃时,预热温度对尺寸精度影响不大,当预热温度大于60℃时,成型尺寸随着预热温度的增加而增大。

基于SLS原型的快速(重力)铸造工艺

结合SLS快速成形和铸造工艺可以实现金属零件的快速铸造。根据原型材料可熔融和烧失的特性,制定了类似于熔模铸造的快速铸造工艺方案。讨论了快速金属铸件的特点,对快速铸造工艺提出了成功率高、成形性好和性能较高的要求。分析了面向金属零件快速铸造的重力铸造工艺并以实例说明,顶注式浇注系统适用于结构简单且高度不大的快速零件,而阶梯式浇注系统适用于中大型和复杂程度较高的铸件。

SLS成型机的粉末预热过程研究

对成型机工作腔的一般预热方法的预热过程进行了分析 ,研究了辐射预热的热流密度对粉末预热温度的影响 ,提出了热流密度场模型 ,并与实验测得的预热温度场进行了比较 。