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3D Printed Ordered and Stochastic Foams

Detailed Technology Description
We provided a method for fabricating 3D printed foamstructures. Our proof of concept studies show that we can tune a material’selastic modulus and density over a range of two orders of magnitude. The resultingfine grained cellular structures/foams are suitable for use in a wide range offields ranging from bioengineering, to robotics to food printing.
Others

Publications

· Jeffrey Lipton and Hod Lipson. “Systems andmethods for freeform fabrication of foamed structures” US Patent 9,079,337Issued July 2015.

· Jeffrey I. Lipton & Hod Lipson “3D Printing VariableStiffness Foams Using Viscous Thread Instability” Scientific Reports volume 6,Article number: 29996 doi:10.1038/srep29996

· Lipton, J. I., Cutler, M., Nigl, F., Cohen, D. & Lipson,H. “Additive manufacturing for the food industry.” Trends in Food Science &Technology 43(1), 114–123 (2015). https://doi.org/10.1016/j.tifs.2015.02.004

· Jeffrey Lipton, Mathew Boban, Jonathan Hiller, Hod Lipson.“FREEFORM FABRICATION OF STOCHASTIC AND ORDERED CELLULAR STRUCTURES” http://sffsymposium.engr.utexas.edu/Manuscripts/2010/2010-63-Lipton.pdf

*Abstract
Technology Overview

Cellular materials provide a unique challenge to 3Dprinting technology. Such materials have unique properties of low mass, highstrength, and good insulation properties. To produce such cellular structures,3D printing systems must produce a microstructure with a feature sizesignificantly lower than the resolution of the printing process.

 

To achieve this, our researchers have taken advantageof the coiling patterns created by flowing of viscous liquids and implemented atechnique to create a ‘stochastic’ or semi-random pore structure in theresultant 3D printed foam. By controlling the flow rate and translation speedof the print head, the size of the coils and the pores in the foam can befinely controlled. The pores do not require any additional computation totranslate a solid geometry into a stochastic foam.

 

Potential Applications

  • 3D printing of porous objects
  • Catalytic Converters
  • Filters
  • Food Products
  • Acoustic Dampers
  • Energy Absorbers
  • Thermal Insulators
  • Medical Implants

 

Advantages

  • Tunable stiffness, density and compressibility
  • Suitable for a wide range of materials
  • Tunable average pore size
  • Minimal computational requirements as pore structure doesn’tneed to be explicitly defined


Keywords: Physical Sciences, Engineering, Materials,Composites, Polymer, Device Manufacturing, Robotics, 3D Printing, MaterialsFabrication, Aerospace, Materials Science, Manufacturing, AdditiveManufacturing, Printing, Industrial Bioproduction, Tissue Engineering, NovelProcesses
*Licensing
Carolyn A. Theodorecat42@cornell.edu607 254 4514
Country/Region
USA

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