3D printed and laser processing of sensors on 3D surfaces
Project challenges
This project was to investigate the capability of producing three-dimensional electronic sensor(s) on 3D objects, utilising the Material Jetting method, commonly referred to as 3D Printing. The adoption of novel technologies is critical in developing leading edge solutions for industrial applications.
Business challenge
Product Innovation
Sector
Road & Rail
Technology or capability
Additive Manufacturing
Laser Processing
Manufacturing Systems
Process Design
Project Challenges
This project was to investigate the capability of producing three-dimensional electronic sensor(s) on 3D objects, utilising the Material Jetting method, commonly referred to as 3D Printing. The adoption of novel technologies is critical in developing leading edge solutions for industrial applications.
The research was to review and demonstrate use case(s), currently impossible to produce via traditional methods. The technique and the scientific discovery aimed to unlock potential process for monitoring and provide valuable feedback directly from source.
The primary example here was to demonstrate RFID on train track sections.
MTC's Solution
- A feasibility study of RFID sensors and additive technologies was used to guide the work.
- The Dragonfly LDM can inkjet print a silver ink and a dielectric within the same layer to achieve 3D electronics. This method allows novel structures to be created. The Dragonfly was used to trial the sensors on 2D surfaces.
- Optomec 5-axis printer is able to print a range of inks onto 3D surfaces. This printer was used to print the sensors onto 3D surfaces, including a train track section.
- Laser processing offers a viable solution to trimming printed materials to achieve good edge roughness, and for creating good surface preparation and appropriate roughness of the material to be printed onto to promote adhesion of printed inks.
The Outcome
Both processes were successfully demonstrated and an in depth understanding of the application techniques was developed.
Using the additive manufacturing techniques for this development enabled high quality, good process control and minimal silver ink usage for developing the design and our competence in developing this process, which ultimately reduces costs.
Through this research, printed antennas are shown to be achievable on a 3D surface, making them adaptable for other applications. This improves quality of future designs by having more flexibility in design. It was identified that the need for component(s) assembly on thick 3D object/shape is extremely challenging as currently dedicated systems are only just becoming available.
Benefits to the Client
Much of the research demonstrates to the customer the viability of the technologies in producing 3D electronics. Many challenges still exist such as:
- Interlinking the various processes into a singular production line.
- Refining compatibility between materials selected to make fit for purpose.
In this project the choice of silver deposition and sintering system identified at an early stage saved research time and cost.
A reduction in resistance of between 13-36% achieved by laser sintering on the representative circuits demonstrated feasibility for quality improvements.