3D Printing Macroscale Engineered Materials Using Ultrasound Directed Self‐Assembly and Stereolithography

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Abstract
A manufacturing process to 3D print engineered materials comprised of a user‐specified pattern of nano‐ or microparticles embedded in a polymer matrix material is described. The materials are printed layer‐by‐layer using stereolithography, and in each layer, ultrasound directed self‐assembly is employed to organize a user‐specified pattern of particles. This process allows manufacturing macroscale 3D materials with a user‐specified microstructure consisting of particles of any material, and contrasts with existing processes, which are often limited to laboratory scale, specific materials, and/or 2D implementations. Using this manufacturing process, 3D printing of macroscale multilayer engineered materials containing a Bouligand microstructure commonly found in composite laminate and biological materials is demonstrated. Additionally, engineered materials containing a pattern of electrically conductive nickel‐coated carbon fibers are fabricated, which illustrate the feasibility of 3D printing structures with embedded insulated electrical wiring. This process finds application in manufacturing of multifunctional composite materials.
Funding Information
  • Army Research Office (W911NF‐16‐1‐0457)

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