October AMP_Digital

A D V A N C E D M A T E R I A L S & P R O C E S S E S | O C T O B E R 2 0 1 9 3 4 XJet’s NanoParticle Jetting (NPJ) tech- nology delivers a breakthrough advan- tage with its ability to reach near-net shape of parts. The accuracy afford- ed by NPJ technology produces parts with excellent shape and dimension- al tolerance, meaning less machin- ing is required, further reducing costs and timescales. This technology, which is different from other AM processes such as stere- olithography, digital light processing, and binder jetting, delivers high-quali- ty ceramic parts with smooth surfaces, superfine details, high density, and ex- cellent dimensional tolerance. This is achieved using the dispersion of nano- sized ceramic particles that are sus- pended in a liquid formula and jetted from inkjet nozzles, building very thin layers. The various shapes and sizes of the nanoparticles allow for natural packing and high density of the mate- rial, resulting in strong, tough, and hard ceramic parts. Unlike typical ceramic AM tech- nologies that use the same material for both the build and support structures, NPJ uses a different material for sup- port. The ability to jet more than one material simultaneously enables the system to use a separate proprietary material to provide support during the build; this material is soluble and eas- ily disintegrates from the manufac- tured part afterward. Cavities and fine details can be created with no concern that they will be harmed in the support- removal process, as might occur with other technologies. The technology also ensures that the whole process offers operational advantages, as it is productive, efficient, safe, and simple to use. Production can begin immediately once a part has been designed, enabling manufacturers to accelerate production cycles, and the liquid ceramic dispersion is contained in enclosed cartridges, offering safe and easy-to-use material handling. Ceramic additive manufacturing is poised to enable a whole new range of applications and uses that were simply not possible before, such as conformal cooling channels in mold inserts, per- sonalized implants, and other medical support devices, as well as creating complex geometries that will reduce part weight while optimizing strength. ceramic as one of the most electrical- ly insulating materials, Medtech then faced a manufacturing challenge. Tra- ditional methods could not achieve the complex geometries required, and the company was unable to find a ce- ramic-based 3D printer capable of achieving the fine detail and smooth surfaces required for the internal struc- ture of the device. However, the ad- vances delivered by NPJ technology, including high detailing, finish, and ac- curacy, make ceramic AM an ideal solu- tion for this application. The University of Delaware (UDEL) faced a similar dilemma when one of its research teams developed a cut- ting-edge technology for mathemat- ically designing an antenna called passive beam steering for, among oth- er applications, solving a crucial prob- lem in the roll-out of the 5G network. In comparison to 4G/3G, 5G signals deliv- er data 10-20 times faster, but they are more sensitive to objects and inference, requiring a vast increase in the number of antennas covering the area. Existing antenna technology is simply too ex- pensive to enable the successful scaling up of infrastructure required by 5G. Mark Mirotznik, professor of elec- trical engineering at UDEL, and his team developed special software and algo- rithms to enable the design of small, lightweight, and cost-effective 5G an- tennas. The issue facing the university was that, seemingly, no manufactur- ing process existed to produce the lens with the complex structure, small chan- nels, and material properties required. Discovering NPJ technology solved UDEL’s frustration in achieving both the material characteristics and especially the dielectric constant, combined with the geometric properties required. Ca- pable of producing the inner walls of each channel with the accuracy and smoothness required to retain wave di- rection, XJet’s ceramic is an isotropic, 100% density ceramic with the right di- electric constant that does not absorb and weaken the signal. Applications such as these are paving the way for myriad industries to experience the capabilities of ceramic AM. While metal and plastic AM show The accuracy afforded by NPJ technology produces parts such as Medtech’s cryo- therapy tubes with excellent shape and dimensional tolerance. GAME-CHANGING APPLICATIONS One company that is making strides when it comes to ceramic AM is U.S.-based Marvel Medtech. Having de- veloped a technology with the potential to save thousands of lives, dramatical- ly improve patient care, and realize bil- lions of dollars in healthcare savings, Medtech was missing the manufactur- ing method to bring the design to life. Ray Harter, Marvel Medtech presi- dent, and his teamdeveloped a ceramic cryotherapy probe—a key component within a new robotic intervention guid- ance system designed to freeze and de- stroy dangerous but tiny breast cancer tumors and prevent them from grow- ing. To be used during MRI scans, the novel system represents a complete- ly new approach to breast cancer pre- vention. The Marvel Medtech scanner accessory could prove vital for early elimination, removing the need for fu- ture expensive and invasive biopsies and other surgical procedures. The tool used inside an MRI scan- ner must be compatible andwork inside the magnetic field of the MRI. Selecting