Engineered lattice structures fabricated via additive manufacturing (AM) technologies are of great interest for many applications that require high strength and/or stiffness with minimum mass. This paper studies a novel axial lattice extrusion (ALE) AM technique that greatly enhances mechanical properties of polymeric lattice structures. When the novel ALE process was used to produce 84 mm × 84 mm × 84 mm octet truss lattice samples using fiber reinforced ABS, a total of 219,520 polymer interfaces in the lattice beams were eliminated relative to the conventional 3D printing alternative. Microscopic examination revealed near perfect alignment of the chopped carbon fibers with axes of the cylindrical beams that make up the lattice structure. The greatly enhanced beam quality with fiber reinforcement resulted in excellent mechanical properties. Compression testing yielded an average relative compressive strength of 17.4 MPa and an average modulus of 162.8 MPa. These properties rate very strongly relative to other published work, and indicate that the ALE process shows great potential for fabrication of high-strength, lightweight, large-scale, carbon-fiber composite components. The paper also contributes a modeling approach to finite element analysis (FEA) that captures the highly orthotropic properties of carbon fiber lattice beams. The diagonal shear failure mode predicted via the FEA model was in good agreement with experimentally observed results.

Magnetohydrodynamic Jet Printing (MJP) is a novel additive manufacturing technique that offers tremendous promise for the fabrication of highly conductive electronic circuits with excellent adhesion on flexible substrates. MJP is an on-demand droplet jetting process in which the fluid is molten metal rather than a conductive nanoparticle ink. The work reported here examines the influence of drop spacing and jetting frequency on line morphology and electrical resistivity. Furthermore, the equivalent wire gauge of printed lines is estimated as a function of the drop volume and drop spacing. Under optimized jetting conditions, electrical resistivity as low as 3.2 ΜΩ cm (equivalent to bulk resistivity) has been achieved in aluminum 4043 alloy printed onto flexible polyimide. Little or no substrate cleaning is needed prior to printing, and post processing steps such as drying and curing are eliminated with this technique. The process uses metal wire as the feedstock material, making it significantly less expensive than conventional nanoparticle ink printing techniques.

This paper demonstrates an easily prepared novel material and approach to producing aligned nickel (Ni) nanowires having unique and customizable structures on a variety of substrates for electronic and magnetic applications. This is a new approach to producing printed metallic Ni structures from precursor materials, and it provides a novel technique for nanowire formation during reduction. This homogeneous solution can be printed in ambient conditions, and it forms aligned elemental Ni nanowires over large areas upon heating in the presence of a magnetic field. The use of templates or subsequent purification are not required. This technique is very flexible, and allows the preparation of unique patterns of nanowires which provides opportunities to produce structures with enhanced anisotropic electrical and magnetic properties. An example of this is the unique fabrication of aligned nanowire grids by overlaying layers of nanowires oriented at different angles with respect to each other. The resistivity of printed and cured films was found to be as low as 560 µΩ∙cm. The saturation magnetization was measured to be 30 emu∙g⁻¹, which is comparable to bulk Ni. Magnetic anisotropy was induced with an axis along the direction of the applied magnetic field, giving soft magnetic properties.