Unlocking Larger Scales and Aspect Ratios in 3D Printed Glass: Coupling Active Mixing and UV Curing for Advanced Printability and Crack Resistance

Walton, Beck L.; Dudukovic, Nikola A.; Johnson, Jason; Yee, Timothy D.; Nguyen, Du T.; Ellis, Megan E.; Porcincula, Dominique H.; Krikorian, Caitlyn C.; Duoss, Eric B.; Dylla‐Spears, Rebecca J.

doi:10.1002/admt.202401284

Unlocking Larger Scales and Aspect Ratios in 3D Printed Glass: Coupling Active Mixing and UV Curing for Advanced Printability and Crack Resistance

Journal Article · Sun Nov 24 23:00:00 EST 2024 · Advanced Materials Technologies

DOI:https://doi.org/10.1002/admt.202401284· OSTI ID:2496856

Walton, Beck L. ^[1]; Dudukovic, Nikola A. ^[1]; Johnson, Jason ^[2]; Yee, Timothy D. ^[1]; Nguyen, Du T. ^[1]; Ellis, Megan E. ^[1]; Porcincula, Dominique H. ^[1]; Krikorian, Caitlyn C. ^[1]; Duoss, Eric B. ^[1]; ^[1]

Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)
Purdue Univ., West Lafayette, IN (United States)

Recent developments in additive manufacturing (AM) of glass via silica-filled inks have facilitated fabrication of previously unattainable geometries and compositions. However, the maximum processable size of 15 mm limits the use of these prints in applications such as optics. A key limitation lies in the trade-off between material printability and green strength: increasing silica content in the feedstock improves crack resistance and reduces shrinkage but results in dramatic changes in viscoelastic properties that hinder flowability. Here, this paper presents a novel approach that offers expanded versatility in processable size, feedstock formulation, and printing. Described here is a direct ink writing (DIW) system coupled with an active high-shear micromixer and UV light source, capable of simultaneously printing multiple inks with a wide range of rheological properties. Choice of silica sourc, solvent, UV-curable binder, and dispersant is used to tune the ink rheology and improve printability and mechanical properties. Imparting high shear with the micromixer while UV-curing the extrudate allows for increased ink viscosities and reduced nozzle diameters, enabling printing finer feature sizes. With these advances, thin-walled high-aspect ratio structures and a crack-free glass disk measuring 44 mm in diameter are demonstrated, an increase of 3× in the greatest dimension compared to current state-of-the-art.

View Accepted Manuscript (DOE)

Research Organization:: Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)

Sponsoring Organization:: USDOE National Nuclear Security Administration (NNSA)

Grant/Contract Number:: AC52-07NA27344

OSTI ID:: 2496856

Report Number(s):: LLNL--JRNL-854056; 1082245

Journal Information:: Advanced Materials Technologies, Journal Name: Advanced Materials Technologies Journal Issue: 6 Vol. 10; ISSN 2365-709X

Publisher:: WileyCopyright Statement

Country of Publication:: United States

Language:: English

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36 MATERIALS SCIENCE
UV curing
additive manufacturing
direct ink write
glass
optics
rheology

Unlocking Larger Scales and Aspect Ratios in 3D Printed Glass: Coupling Active Mixing and UV Curing for Advanced Printability and Crack Resistance

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