Additive manufacturing electronics on 3D objects
Project challenges
The project was split into 4 parts:
- The 1st package was to look at the 3D Additive manufacturing state of the art, equipment, processes, design rules and advances in ink technology.
- The 2nd work package is to look at surface finish on metal and polymer objects.
- The 3rd is to design some basic strain gauges sensors and antennas on 3D structures.
- And final work package is to review and establish environmental testing for 3D objects.
Business challenge
Product Innovation
Sector
Defence & Security
Technology or capability
Automation & Robotics
Additive Manufacturing
Manufacturing Systems
Materials Engineering
Process Design
Project Challenges
The project was split into 4 parts:
- The 1st package was to look at the 3D Additive manufacturing state of the art, equipment, processes, design rules and advances in ink technology.
- The 2nd work package is to look at surface finish on metal and polymer objects.
- The 3rd is to design some basic strain gauges sensors and antennas on 3D structures.
- And final work package is to review and establish environmental testing for 3D objects.
MTC's Solution
A general literature review was performed to look at the leading players in the additive world. Also, all available software packages have been reviewed to assess its capability.
Three types of metals have been selected: copper, steel and aluminium. Laser ablation process have been used to texture finish and get coarse, semi coarse and smooth surfaces. 4 different thicknesses of dielectric have been printed on it with metal tracks to assess sample conductivity. Additional adhesion tests have been used to determine an optimum surface finish.
Strain gauge sensors have been designed, printed and measured.
A review of environmental tests suitable for 3D parts has performed. A review of conditions and processes against standards with costings enables the customer to make informed decisions.
The Outcome
A report on ‘Literature, Equipment, Process, Software & Design Rules for Additive Manufacturing Electronics on 3D objects’ has been created.
The process flow for AME on 3D objects has been defined. Various printing methods were used to print dielectric and conductive materials and their capabilities and limitations have been outlined. Various sintering methods, typically used to dry, cure and sinter conductive materials have been identified from literature and compared.
Key equipment manufacturers for printing, as well as post-processing steps, have been identified and reviewed with capabilities and limitations identified.
A materials review has been conducted on conductive, dielectric inks/pastes. Materials supply chain mechanisms along with available materials for different equipment suppliers, key material suppliers and key characteristics of the material have been specified.
Design guidelines to be considered when designing electronics applications for Nano Dimension and Optomec systems have been specified.
Benefits to the Client
- The report created is a convenient tool for the client to select appropriate technology and assess viability of the processes for future products.
- Laser texturing allows for optimum surface preparation to achieve required adhesion.
- Reviews of environmental equipment and testing providers allows for appropriate hardware selection for particular test conditions.