Metal parts 3D printing technology has always been called a development branch of high difficulty and high standard in the field of 3D printing . It has a pivotal position in industrial manufacturing and is an important development direction of today's manufacturing technology. Copper is a versatile metal material that plays an important role in many aspects of machinery manufacturing, electronics, and transportation equipment. The use of traditional methods to fabricate copper is not only costly, it wastes material, but it is also very difficult. But thanks to the latest research projects at Virginia Tech (VT), this situation may soon change.

It is understood that the latest research on VT is a developing copper material 3D printer led by Dr. Christopher Willams, associate professor of mechanical engineering. Although metal 3D printers are already common, many companies have developed several more mature metal 3D printers, but the machine that Dr. Willams is working on is still slightly different: the metal material it uses - copper, is a A material that is very difficult to machine.

“The process we are developing is called adhesive jetting. Specifically, the adhesive is selectively sprayed onto the copper metal powder bed through the ink jet head, one layer at a time. When the entire object is printed in this way, we will Put it in the furnace for sintering and fusion, and finally get the real metal parts."

Although this process is capable of mass producing a variety of copper components, it still has some problems to be solved. The biggest problem is that these parts are formed by printing first and then sintering, which causes very little air residue between the copper powder particles. Therefore, parts made by this process are more vulnerable than parts made by conventional methods. However, the R&D team is not without countermeasures. They are currently testing the hypothesis that by using a nanosuspension binder to fill the voids between the copper powder particles, the density of the printed parts is increased and the bond between adjacent powder particles during sintering is enhanced.

Copper powder particles and air in the gap at the microscopic scale

In fact, the team is planning to add nanoparticles to the spray glue, hoping to fill the gaps that occur during the sintering process.

“We hope this will improve the sintering effect of copper, the mechanical properties of the final part and its electrical conductivity,” explains Dr. Williams. “We want to share these results so that engineers can design energy and heat in a more relaxed way. And structural applications to design arbitrarily complex copper parts."

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