Sergio Ferrero

Additive Manufacturing for Electronics (AME) techniques are currently becoming more widespread as they allow for the rapid production of electronic devices with confined costs. In this context, AME represents a relatively novel fabrication technique when used for power electronics applications. The research presented in this paper is focused on the investigation of the feasibility of inkjet-based AME for the fabrication of structures and components for power electronics applications. Seven circuit models for a power module were developed and printed with a multimaterial 3D printer. The models were then analyzed to optimize their design in terms of dimensional accuracy. Furthermore, the electrical conductivity and the magnetic field of one of the devices were examined with numerical simulation tools to verify its effectiveness and efficiency when compared to factory-built power modules. The resulting devices could be considered for coupling and improving the functionality of a module built using non-AME technology, showing that custom-built electronic devices of this kind can be a valid upgrade to the current state of the art. Thus, AME-fabricated devices might be considered as potential enablers for next-generation wide-bandgap (WBG) devices.

Nowadays, Additive Manufacturing for Electronics (AME) is gaining ground in device fabrication for the numerous advantages of these types of manufacturing technologies, such as fast production processes, freeform design, and low-cost prototyping. In this scenario, the proposed research work is focused on evaluating an innovative strategy for a common issue in power electronics, which is related to the generation of hotspots. To face this problem, the 3D printing of ceramic substrates with different high surface areas was studied to improve thermal dissipation. Together with improved thermal management, the upper surface of the devices enabled the deposition of a desired conductive pattern and the bonding of bare die components for device fabrication. Finally, thermal exchange was monitored to verify the efficacy and efficiency of the devices’ dissipation capabilities. The proposed models exhibited a 70% temperature reduction upon transitioning from air to water. Furthermore, the operating temperature remained stable for 10 min, meeting the specific requirements of the intended application.

Reed sensors play an important role in improving the safety, reliability, and efficiency of modern electric vehicles. Our study evaluates their performance by measuring the switching distance under five different configurations of a cylindrical magnet using a 3D-printed test fixture. Statistical analysis revealed that the right-shift-upward configuration yielded the best performance, significantly reducing the release distance. Building on this, a prototype housing was developed using Selective Laser Sintering with polybutylene terephthalate, and a stainless-steel spring was incorporated to enhance sensitivity and reliability. The spring integration reduced the activation distance to 2.3 mm, which is an improvement of up to 60%, and it also significantly improved the consistency of the results. These outcomes demonstrate a practical method for manufacturing more reliable reed sensors for automotive sensing technology.

An advanced anodic stripping voltammetry (ASV)-based Micro Electro Mechanical System (MEMS) sensor for cadmium (Cd) detection is presented in this study, which is cost-effective and efficient for in situ water monitoring, providing a crucial early warning mechanism, streamlining environmental monitoring, and facilitating timely intervention to safeguard public health and environmental safety. The rationale behind this work is to address the critical need for an in situ monitoring system for cadmium (Cd) in freshwater sources, particularly those adjacent to agricultural fields. Cd(II) is a highly toxic heavy metal that poses a significant threat to agricultural ecosystems and human health due to its rapid bioaccumulation in plants and subsequent entry into the food chain. The developed analytic device is composed of a commercial mercury salt-modified graphite screen-printed electrode (SPE) with a custom-designed innovative polydimethylsiloxane (PDMS) flow detection cell. The flow cell was prototyped using 3D printing and replica moulding, with its design and performance validated through COMSOL Multiphysics simulations to optimize inflow conditions and ensure maximum analyte dispersion on the working electrode surface. Chemical detection was performed using square wave voltammetry, demonstrating a linear response for Cd(II) concentrations of 0 to 20 µg/L. The system exhibited robust analytical performance, enabling 25–30 daily analyses with consistent sensitivity within the Limit of Detection (LoD) set by the law of 3 µg/L.

Nanocomposite laminates containing carbon fibers, epoxy, and multiwalled carbon nanotubes were fabricated using a vacuum bag process. Ecofriendly ionic liquid (5 wt%)-treated multiwalled carbon nanotubes (pristine and nickel-coated) were added to the epoxy independently, in amounts ranging from 1 wt% to 3 wt%, in order to tailor the mechanical, electrical, and thermal performance of manufactured carbon fiber epoxy composite laminates. These nanocomposite laminates were later characterized through flexural testing, dynamic mechanical analysis, impedance spectroscopy, thermal conductivity tests, and FTIR spectroscopy to evaluate their suitability for battery pack applications. The findings showed that both types of multiwalled carbon nanotubes exhibited multifaceted effects on the properties of bulk hybrid carbon fiber epoxy nanocomposite laminates. For instance, the flexural strength of the composites containing 3.0 wt% of ionic liquid-treated pristine multiwalled carbon nanotubes reached 802.8 MPa, the flexural modulus was 88.21 GPa, and the storage modulus was 18.2 GPa, while the loss modulus peaked at 1.76 GPa. The thermal conductivity of the composites ranged from 0.38869 W/(m · K) to 0.69772 W/(m · K), and the electrical resistance decreased significantly with the addition of MWCNTs, reaching a minimum of 29.89 Ω for CFRPIP-1.5 wt%. The structural performance of hybrid nanocomposites containing ionic liquid-treated pristine multiwalled carbon nanotubes was higher than that of the hybrid nanocomposite of ionic liquid-treated Ni-coated multiwalled carbon nanotubes, although the latter was found to possess better functional performance.

Nowadays, additive manufacturing technologies have impacted different engineering sectors. Three- and four-dimensional printing techniques are increasingly used in soft and flexible electronics thanks to the possibility of working contemporarily with several materials on various substrates. The materials portfolio is wide, as well as printing processes. Shape memory polymers, together with composites, have gained great success in the electronic field and are becoming increasingly popular for fabricating pH, temperature, humidity, and stress sensors that are integrated into wearable, stretchable, and flexible devices, as well as for the fabrication of communication devices, such as antennas. Here, we report an overview of the state of the art about the application of 4D printing technologies and smart materials in electronics.

MEMS devices are more and more commonly used as sensors, actuators, and microfluidic devices in different fields like electronics, opto-electronics, and biomedical engineering. Traditional fabrication technologies cannot meet the growing demand for device miniaturisation and fabrication time reduction, especially when customised devices are required. That is why additive manufacturing technologies are increasingly applied to MEMS. In this review, attention is focused on the Italian scenario in regard to 3D-printed MEMS, studying the techniques and materials used for their fabrication. To this aim, research has been conducted as follows: first, the commonly applied 3D-printing technologies for MEMS manufacturing have been illustrated, then some examples of 3D-printed MEMS have been reported. After that, the typical materials for these technologies have been presented, and finally, some examples of their application in MEMS fabrication have been described. In conclusion, the application of 3D-printing techniques, instead of traditional processes, is a growing trend in Italy, where some exciting and promising results have already been obtained, due to these new selected technologies and the new materials involved.

Concerning environmental safety and mitigating the risk of water pollution, the electroplating industry, historically reliant on the use of elevated concentrations of heavy metals to achieve high-quality products, faces a crucial challenge in monitoring wastewater enriched with these metals, notorious for their adverse effects on ecosystems and human health. Chromium, in both oxidation states Cr (III) and Cr (VI), emerges as a prominently employed metal, yielding noteworthy outcomes throughout the galvanisation process. This research showcases the prototype of an automatic in situ sensor tailored to industry sustainability efforts to facilitate real-time monitoring and efficient water management. This custom sensor, characterized by sensitivity, reliability, and user-friendliness, utilizes UV-Vis colorimetric principle to detect Cr in both oxidation forms ranging from grams per litre (g/L) to parts per million (ppm). This is made possible by the unique vibrant colours induced by chromium ions, enabling the precise measurement of analyte concentrations. Thanks to 3D printing, this sensor system interacts with customized parts, designed and validated through simulation processes, for filtering out particulate that may interfere with the analysis. The outcome represents a synergistic blend of technology and environmental responsibility, aligning industrial processes with the goal of safeguarding water resources and ecosystems.

Modifying material properties within a specific spatial region is a pivotal stage in the fabrication of microelectronic devices. Laser annealing emerges as a compelling technology, offering precise control over the crystalline structure of semiconductor materials and facilitating the activation of doping ions in localized regions. This obviates the necessity for annealing the entire wafer or device. The objective of this review is to comprehensively investigate laser annealing processes specifically targeting the crystallization of amorphous silicon (Si) and silicon carbide (SiC) samples. Silicon finds extensive use in diverse applications, including microelectronics and solar cells, while SiC serves as a crucial material for developing components designed to operate in challenging environments or high-power integrated devices. The review commences with an exploration of the underlying theory and fundamentals of laser annealing techniques. It then delves into an analysis of the most pertinent studies focused on the crystallization of these two semiconductor materials.