Analytical Study and Experimental Verification of Shear-Thinning Ink Flow in Direct Ink Writing Process

Guo, Zipeng; Fei, Fan; Song, Xuan; Zhou, Chi

doi:10.1115/1.4056926

Analytical Study and Experimental Verification of Shear-Thinning Ink Flow in Direct Ink Writing Process

Journal Article · 15 March 2023 · Journal of Manufacturing Science and Engineering

DOI:https://doi.org/10.1115/1.4056926· OSTI ID:2418649

Guo, Zipeng ^[1]; Fei, Fan; Song, Xuan; Zhou, Chi

OSTI

Abstract

Direct ink writing (DIW) process is a facile additive manufacturing technology to fabricate three-dimensional (3D) objects with various materials. Its versatility has attracted considerable interest in academia and industry in recent years. As such, upsurging endeavors are invested in advancing the ink flow behaviors in order to optimize the process resolution and the printing quality. However, so far, the physical phenomena during the DIW process are not revealed in detail, leaving a research gap between the physical experiments and its underlying theories. Here, we present a comprehensive analytical study of non-Newtonian ink flow behavior during the DIW process. Different syringe-nozzle geometries are modeled for the comparative case studies. By using the computational fluid dynamics (CFD) simulation method, we reveal the shear-thinning property during the ink extrusion process. Besides, we study the viscosity, shear stress, and velocity fields, and analyze the advantages and drawbacks of each syringe-nozzle model. On the basis of these investigations and analyses, we propose an improved syringe-nozzle geometry for stable extrusion and high printing quality. A set of DIW printing experiments and rheological characterizations are carried out to verify the simulation studies. The results developed in this work offer an in-depth understanding of the ink flow behavior in the DIW process, providing valuable guidelines for optimizing the physical DIW configuration toward high-resolution printing and, consequently, improving the performance of DIW-printed objects.

Research Organization:: State Univ. of New York (SUNY), Albany, NY (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

DOE Contract Number:: EE0008675

OSTI ID:: 2418649

Journal Information:: Journal of Manufacturing Science and Engineering, Journal Name: Journal of Manufacturing Science and Engineering Journal Issue: 7 Vol. 145; ISSN 1087-1357

Publisher:: ASME

Country of Publication:: United States

Language:: English

References (58)

A fully explicit three‐step SPH algorithm for simulation of non‐Newtonian fluid flow Hosseini, S. M.; Manzari, M. T.; Hannani, S. K. International Journal of Numerical Methods for Heat & Fluid Flow, Vol. 17, Issue 7 https://doi.org/10.1108/09615530710777976	journal	September 2007
Towards the Experimentally-Informed In Silico Nozzle Design Optimization for Extrusion-Based Bioprinting of Shear-Thinning Hydrogels Reina-Romo, Esther; Mandal, Sourav; Amorim, Paulo Frontiers in Bioengineering and Biotechnology, Vol. 9 https://doi.org/10.3389/fbioe.2021.701778	journal	August 2021
Direct Printing for Additive Patterning of Silver Nanowires for Stretchable Sensor and Display Applications Cai, Le; Zhang, Suoming; Zhang, Yiheng Advanced Materials Technologies, Vol. 3, Issue 2 https://doi.org/10.1002/admt.201700232	journal	November 2017
Direct ink writing of three-dimensional thermoelectric microarchitectures Kim, Fredrick; Yang, Seong Eun; Ju, Hyejin Nature Electronics, Vol. 4, Issue 8 https://doi.org/10.1038/s41928-021-00622-9	journal	August 2021
Improving 3D printing process of lemon juice gel based on fluid flow numerical simulation Yang, Fanli; Guo, Chaofan; Zhang, Min LWT, Vol. 102 https://doi.org/10.1016/j.lwt.2018.12.031	journal	March 2019
Concentrated hydroxyapatite inks for direct-write assembly of 3-D periodic scaffolds Michna, Sarah; Wu, Willie; Lewis, Jennifer A. Biomaterials, Vol. 26, Issue 28 https://doi.org/10.1016/j.biomaterials.2005.02.040	journal	October 2005
Efficient Fabrication of Polycaprolactone Scaffolds for Printing Hybrid Tissue-Engineered Constructs Sodupe Ortega, Enrique; Sanz-Garcia, Andres; Pernia-Espinoza, Alpha Materials, Vol. 12, Issue 4 https://doi.org/10.3390/ma12040613	journal	February 2019
Architected cellular ceramics with tailored stiffness via direct foam writing Muth, Joseph T.; Dixon, Patrick G.; Woish, Logan Proceedings of the National Academy of Sciences, Vol. 114, Issue 8 https://doi.org/10.1073/pnas.1616769114	journal	February 2017
An overview of extrusion-based bioprinting with a focus on induced shear stress and its effect on cell viability Boularaoui, Selwa; Al Hussein, Ghada; Khan, Kamran A. Bioprinting, Vol. 20 https://doi.org/10.1016/j.bprint.2020.e00093	journal	December 2020
3D Printing of Interdigitated Dielectric Elastomer Actuators Chortos, Alex; Hajiesmaili, Ehsan; Morales, Javier Advanced Functional Materials, Vol. 30, Issue 1 https://doi.org/10.1002/adfm.201907375	journal	November 2019
3D-Printing of Lightweight Cellular Composites Compton, Brett G.; Lewis, Jennifer A. Advanced Materials, Vol. 26, Issue 34, p. 5930-5935 https://doi.org/10.1002/adma.201401804	journal	June 2014
Three-Dimensional-Printed Silica Aerogels for Thermal Insulation by Directly Writing Temperature-Induced Solidifiable Inks Wang, Lukai; Feng, Junzong; Luo, Yi ACS Applied Materials & Interfaces, Vol. 13, Issue 34 https://doi.org/10.1021/acsami.1c12020	journal	August 2021
3D Printing of Emulsions and Foams into Hierarchical Porous Ceramics Minas, Clara; Carnelli, Davide; Tervoort, Elena Advanced Materials, Vol. 28, Issue 45 https://doi.org/10.1002/adma.201603390	journal	September 2016
Relation between ordering and shear thinning in colloidal suspensions Xu, X.; Rice, S. A.; Dinner, A. R. Proceedings of the National Academy of Sciences, Vol. 110, Issue 10 https://doi.org/10.1073/pnas.1301055110	journal	February 2013
Additive Manufacturing of Porous Ceramics With Foaming Agent Guo, Zipeng; An, Lu; Lakshmanan, Sushil Journal of Manufacturing Science and Engineering, Vol. 144, Issue 2 https://doi.org/10.1115/1.4051828	journal	August 2021
3D printing technologies for electrochemical energy storage Zhang, Feng; Wei, Min; Viswanathan, Vilayanur V. Nano Energy, Vol. 40 https://doi.org/10.1016/j.nanoen.2017.08.037	journal	October 2017
CFD simulation of non-Newtonian fluid flow in anaerobic digesters Wu, Binxin; Chen, Shulin Biotechnology and Bioengineering, Vol. 99, Issue 3 https://doi.org/10.1002/bit.21613	journal	January 2007
Recent advances in ink-based additive manufacturing for porous structures Guo, Zipeng; Zhou, Chi Additive Manufacturing, Vol. 48 https://doi.org/10.1016/j.addma.2021.102405	journal	December 2021
Chaotic mixing in three-dimensional microvascular networks fabricated by direct-write assembly Therriault, Daniel; White, Scott R.; Lewis, Jennifer A. Nature Materials, Vol. 2, Issue 4 https://doi.org/10.1038/nmat863	journal	March 2003
High Internal Phase Emulsion for Food-Grade 3D Printing Materials Li, Xiang; Xu, Xianbing; Song, Liang ACS Applied Materials & Interfaces, Vol. 12, Issue 40 https://doi.org/10.1021/acsami.0c11434	journal	September 2020
Flow of Herschel–Bulkley fluids through the Marsh cone Nguyen, V. H.; Rémond, S.; Gallias, J. L. Journal of Non-Newtonian Fluid Mechanics, Vol. 139, Issue 1-2 https://doi.org/10.1016/j.jnnfm.2006.07.009	journal	November 2006
The convergence of non-Newtonian fluids to Navier–Stokes equations Guo, Boling; Guo, Chunxiao Journal of Mathematical Analysis and Applications, Vol. 357, Issue 2 https://doi.org/10.1016/j.jmaa.2009.04.027	journal	September 2009
Hydrodynamic stimulation of dinoflagellate bioluminescence: a computational and experimental study Latz, Michael I.; Juhl, Andrew R.; Ahmed, Abdel M. Journal of Experimental Biology, Vol. 207, Issue 11 https://doi.org/10.1242/jeb.00973	journal	May 2004
A comparative study between syringe-based and screw-based 3D food printers by computational simulation Guo, Chao-Fan; Zhang, Min; Bhandari, Bhesh Computers and Electronics in Agriculture, Vol. 162 https://doi.org/10.1016/j.compag.2019.04.032	journal	July 2019
Assessing the dynamic extrusion-based 3D printing process for power-law fluid using numerical simulation Liu, Qiannan; Zhang, Nana; Wei, Wensong Journal of Food Engineering, Vol. 275 https://doi.org/10.1016/j.jfoodeng.2019.109861	journal	June 2020
Toward digitally controlled catalyst architectures: Hierarchical nanoporous gold via 3D printing Zhu, Cheng; Qi, Zhen; Beck, Victor A. Science Advances, Vol. 4, Issue 8 https://doi.org/10.1126/sciadv.aas9459	journal	August 2018
Cell loaded 3D bioprinted GelMA hydrogels for corneal stroma engineering Kilic Bektas, Cemile; Hasirci, Vasif Biomaterials Science, Vol. 8, Issue 1 https://doi.org/10.1039/C9BM01236B	journal	January 2020
Rheological analysis of Newtonian and non‐Newtonian fluids using Marsh funnel: Experimental study and computational fluid dynamics modeling Li, Zhaochuan; Zheng, Lihui; Huang, Weian Energy Science & Engineering, Vol. 8, Issue 6 https://doi.org/10.1002/ese3.647	journal	February 2020
Controlling Shear Stress in 3D Bioprinting is a Key Factor to Balance Printing Resolution and Stem Cell Integrity Blaeser, Andreas; Duarte Campos, Daniela Filipa; Puster, Uta Advanced Healthcare Materials, Vol. 5, Issue 3 https://doi.org/10.1002/adhm.201500677	journal	December 2015
On approximation of non-Newtonian fluid flow by the finite element method Sváček, Petr Journal of Computational and Applied Mathematics, Vol. 218, Issue 1 https://doi.org/10.1016/j.cam.2007.04.040	journal	August 2008
3D Printing‐Enabled Nanoparticle Alignment: A Review of Mechanisms and Applications Xu, Weiheng; Jambhulkar, Sayli; Ravichandran, Dharneedar Small, Vol. 17, Issue 45 https://doi.org/10.1002/smll.202100817	journal	June 2021
3D printing of dense and porous alkali-activated refractory wastes via Direct Ink Writing (DIW) Coppola, Bartolomeo; Tardivat, Caroline; Richaud, Stéphane Journal of the European Ceramic Society, Vol. 41, Issue 6 https://doi.org/10.1016/j.jeurceramsoc.2021.01.019	journal	June 2021
Resolution and shape in bioprinting: Strategizing towards complex tissue and organ printing Lee, Jia Min; Ng, Wei Long; Yeong, Wai Yee Applied Physics Reviews, Vol. 6, Issue 1 https://doi.org/10.1063/1.5053909	journal	March 2019
Non-Newtonian viscous shear thinning in ionic liquids Burrell, Geoffrey L.; Dunlop, Noel F.; Separovic, Frances Soft Matter, Vol. 6, Issue 9 https://doi.org/10.1039/b916049n	journal	January 2010
General, Vertical, Three-Dimensional Printing of Two-Dimensional Materials with Multiscale Alignment Liang, Zhiqiang; Pei, Yong; Chen, Chaoji ACS Nano, Vol. 13, Issue 11 https://doi.org/10.1021/acsnano.9b04202	journal	October 2019
Ultrastructural Characterization of the Lower Motor System in a Mouse Model of Krabbe Disease Cappello, Valentina; Marchetti, Laura; Parlanti, Paola Scientific Reports, Vol. 6, Issue 1 https://doi.org/10.1038/s41598-016-0001-8	journal	December 2016
Rainbow particle imaging velocimetry for dense 3D fluid velocity imaging Xiong, Jinhui; Idoughi, Ramzi; Aguirre-Pablo, Andres A. ACM Transactions on Graphics, Vol. 36, Issue 4 https://doi.org/10.1145/3072959.3073662	journal	July 2017
Effects of extrusion speed and printing speed on the 3D printing stability of extruded PEEK filament Geng, Peng; Zhao, Ji; Wu, Wenzheng Journal of Manufacturing Processes, Vol. 37 https://doi.org/10.1016/j.jmapro.2018.11.023	journal	January 2019
Ror2 signaling regulates Golgi structure and transport through IFT20 for tumor invasiveness Nishita, Michiru; Park, Seung-Yeol; Nishio, Tadashi Scientific Reports, Vol. 7, Issue 1 https://doi.org/10.1038/s41598-016-0028-x	journal	January 2017
Applications of 3D printing on craniofacial bone repair: A systematic review Maroulakos, Michael; Kamperos, George; Tayebi, Lobat Journal of Dentistry, Vol. 80 https://doi.org/10.1016/j.jdent.2018.11.004	journal	January 2019
Computational Simulation of a Non‐Newtonian Model of the Blood Separation Process De Gruttola, Sandro; Boomsma, Kevin; Poulikakos, Dimos Artificial Organs, Vol. 29, Issue 12 https://doi.org/10.1111/j.1525-1594.2005.00164.x	journal	November 2005
Perspectives on multi-material additive manufacturing Zheng, Xiaoyu; Williams, Christopher; Spadaccini, Christopher M. Journal of Materials Research, Vol. 36, Issue 18 https://doi.org/10.1557/s43578-021-00388-y	journal	September 2021
Shear induced alignment of short nanofibers in 3D printed polymer composites Yunus, Doruk Erdem; Shi, Wentao; Sohrabi, Salman Nanotechnology, Vol. 27, Issue 49 https://doi.org/10.1088/0957-4484/27/49/495302	journal	November 2016
In vivo bone response to 3D periodic hydroxyapatite scaffolds assembled by direct ink writing Simon, Joshua L.; Michna, Sarah; Lewis, Jennifer A. Journal of Biomedical Materials Research Part A, Vol. 83A, Issue 3 https://doi.org/10.1002/jbm.a.31329	journal	December 2007
Tailoring thermal insulation architectures from additive manufacturing An, Lu; Guo, Zipeng; Li, Zheng Nature Communications, Vol. 13, Issue 1 https://doi.org/10.1038/s41467-022-32027-3	journal	July 2022
Cost-Effective Additive Manufacturing of Ambient Pressure-Dried Silica Aerogel Guo, Zipeng; Yang, Ruizhe; Wang, Tianjiao Journal of Manufacturing Science and Engineering, Vol. 143, Issue 1 https://doi.org/10.1115/1.4048740	journal	December 2020
3D Printing by Multiphase Silicone/Water Capillary Inks Roh, Sangchul; Parekh, Dishit P.; Bharti, Bhuvnesh Advanced Materials, Vol. 29, Issue 30 https://doi.org/10.1002/adma.201701554	journal	June 2017
Study on ink flow of silicone rubber for direct ink writing Shao, Yuanrui; Han, Ruijie; Quan, Xudong Journal of Applied Polymer Science, Vol. 138, Issue 33 https://doi.org/10.1002/app.50819	journal	April 2021
Effect of needle geometry on flow rate and cell damage in the dispensing-based biofabrication process Li, Minggan; Tian, Xiaoyu; Schreyer, David J. Biotechnology Progress, Vol. 27, Issue 6 https://doi.org/10.1002/btpr.679	journal	August 2011
Dynamics of Cellulose Nanocrystal Alignment during 3D Printing Hausmann, Michael K.; Rühs, Patrick A.; Siqueira, Gilberto ACS Nano, Vol. 12, Issue 7 https://doi.org/10.1021/acsnano.8b02366	journal	June 2018
Extrusion-Based 3D Printing of Poly(propylene fumarate) in a Full-Factorial Design Trachtenberg, Jordan E.; Placone, Jesse K.; Smith, Brandon T. ACS Biomaterials Science & Engineering, Vol. 2, Issue 10 https://doi.org/10.1021/acsbiomaterials.6b00026	journal	March 2016
Analytical model to predict the extrusion force as a function of the layer height, in extrusion based 3D printing Percoco, Gianluca; Arleo, Luca; Stano, Gianni Additive Manufacturing, Vol. 38 https://doi.org/10.1016/j.addma.2020.101791	journal	February 2021
Cellulose-Nanofiber-Enabled 3D Printing of a Carbon-Nanotube Microfiber Network Li, Yuanyuan; Zhu, Hongli; Wang, Yibo Small Methods, Vol. 1, Issue 10 https://doi.org/10.1002/smtd.201700222	journal	September 2017
Mechanics of nozzle clogging during direct ink writing of fiber-reinforced composites Croom, Brendan P.; Abbott, Andrew; Kemp, James W. Additive Manufacturing, Vol. 37 https://doi.org/10.1016/j.addma.2020.101701	journal	January 2021
Additive manufacturing of silica aerogels Zhao, Shanyu; Siqueira, Gilberto; Drdova, Sarka Nature, Vol. 584, Issue 7821 https://doi.org/10.1038/s41586-020-2594-0	journal	August 2020
Hierarchical cellular scaffolds fabricated via direct foam writing using gelled colloidal particle‐stabilized foams as the ink Ren, Bo; Liu, Jingjing; Wang, Yali Journal of the American Ceramic Society, Vol. 102, Issue 11 https://doi.org/10.1111/jace.16543	journal	May 2019
Linear instability of pressure-driven channel flow of a Newtonian and a Herschel-Bulkley fluid Sahu, K. C.; Valluri, P.; Spelt, P. D. M. Physics of Fluids, Vol. 19, Issue 12 https://doi.org/10.1063/1.2814385	journal	December 2007
Biomimetic silicification of 3D polyamine-rich scaffolds assembled by direct ink writing Xu, Mingjie; Gratson, Gregory M.; Duoss, Eric B. Soft Matter, Vol. 2, Issue 3 https://doi.org/10.1039/b517278k	journal	January 2006

Similar Records

Real-time process monitoring for direct ink write additive manufacturing

Patent · 2023 · OSTI ID:2293936

On the cogent formulation of an elastomeric silicone ink material for direct ink write ( DIW ) 3D printing

Journal Article · 2024 · Polymer Engineering and Science · OSTI ID:2329350

Advanced Methods for Direct Ink Write Additive Manufacturing

Technical Report · 2018 · OSTI ID:1418958

Related Subjects

Engineering

Analytical Study and Experimental Verification of Shear-Thinning Ink Flow in Direct Ink Writing Process

Citation Formats

References (58)

Similar Records

Related Subjects