From additive manufacturing to 3D/4D printing. 2, Current techniques, improvements and their limitations

339 Pages·2017·15.13 MB·English

by  André

From Additive Manufacturing to 3D/4D Printing 2
To Laurent and Denis, who allowed me
.
to dedicate myself to additive manufacturing
Series Editor
Jean-Charles Pomerol
From Additive Manufacturing

to 3D/4D Printing 2

Current Techniques, Improvements
and their Limitations

Jean-Claude André
First published 2017 in Great Britain and the United States by ISTE Ltd and John Wiley & Sons, Inc.
Apart from any fair dealing for the purposes of research or private study, or criticism or review, as
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© ISTE Ltd 2017
The rights of Jean-Claude André to be identified as the author of this work have been asserted by him in
accordance with the Copyright, Designs and Patents Act 1988.
Library of Congress Control Number: 2017953144

British Library Cataloguing-in-Publication Data
A CIP record for this book is available from the British Library
ISBN 978-1-78630-120-8
Contents
Acknowledgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxix
Part 1. Incremental Innovations and
Technologies Pushed to their Limits . . . . . . . . . . . . . . . . . . . . . . . . 1
Chapter 1. Incremental Developments of
Processes, Machines and Materials . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2. Undertaking non-layered stereolithography . . . . . . . . . . . . . . . . . . . . 8
1.2.1. Optimizing the light supply within
a single-photon process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2.2. Transparent window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2.3. Gaseous interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2.4. Simultaneous two-photon absorption. . . . . . . . . . . . . . . . . . . . . . 16
1.3. Challenging the notion of layers . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.3.1. Addition of prefabricated structures . . . . . . . . . . . . . . . . . . . . . . 26
1.3.2. Proof of concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.3.3. Synthesis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.4. Optical-quality surface finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.4.1. Glasses lenses and contact lenses . . . . . . . . . . . . . . . . . . . . . . . . 36
vi From Additive Manufacturing to 3D/4D Printing 2
1.4.2. Microlenses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.4.3. Direct lens manufacture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.4.4. Multi-mode optical fiber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.5. Cold-cast metal 3D printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.5.1. Electrolytic deposition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.5.2. Metallic ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.5.3. Laser processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.5.4. Photochemistry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.5.5. Silver metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.5.6. Conducting polymers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.6. Colored objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.7. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.8. Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Part 2. Additive Manufacturing Pushed to its Limits . . . . . . . . . . . . . . . 71
Introduction to Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Chapter 2. µ-Fluidics (or Microfluidics) . . . . . . . . . . . . . . . . . . . . . . . 81
2.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.2. Review of microfluidics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.3. Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.4. Return to additive manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.4.1. Comment 1: LIFT process (Laser-Induced
Forward Transfer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.4.2. Comment 2: FEBID process (Focused Electron
Beam Induced Deposition) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.4.3. Other methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.4.4. Hybrid methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.5. Conclusive outcomes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.6. The converse problem: a potential µ-fluidics
application to additive manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.6.1. 3D sintering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.6.2. Deposition of polymerized particles . . . . . . . . . . . . . . . . . . . . . . 101
2.7. Provisional concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2.8. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.9. Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Contents vii
Chapter 3. 3D Nanomanufacturing,
3D µ-Electronics and µ-Robotics . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.2. 3D nano-facturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.2.1. Smart material: so-called “DNA origami” . . . . . . . . . . . . . . . . . . . 125
3.2.2. Return from additive manufacturing
to standard methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
3.2.3. Comment: nanomaterials and
additive manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3.2.4. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
3.3. 3D µ-electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3.3.1. 2D or 3D electronic circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3.3.2. Subtractive/additive coupling . . . . . . . . . . . . . . . . . . . . . . . . . . 146
3.3.3. µ-Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
3.3.4. Conclusion and aspirations in the sphere . . . . . . . . . . . . . . . . . . . 148
3.4. Actuators and µ-robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3.5. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3.6. Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Part 3. How Should We Go That One Step Further? . . . . . . . . . . . . . . . 163
Chapter 4. A Short Reflection on Spheres
to Explore Their Conditions for Achieving Success . . . . . . . . . . . . . . . 165
4.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.2. Favored spheres of innovation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
4.2.1. How to know where we must
anticipate this technology? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
4.2.2. Opportunities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
4.3. Some conditions to ensure additive manufacturing reaches maturity? . . . . . . 183
4.3.1. Moreover where does additive manufacturing
sit within this interdisciplinarity framework? . . . . . . . . . . . . . . . . . . . . . 186
4.3.2. Observations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
4.3.3. Some possible solutions? . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
4.3.4. Proposed solutions? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
4.4. A positive conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4.5. Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Chapter 5. Questions of Hope and “Unhope” . . . . . . . . . . . . . . . . . . . 213
5.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
5.2. The “lab-tribe” (LT) approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
5.2.1. Context elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
viii From Additive Manufacturing to 3D/4D Printing 2
5.2.2. Some results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
5.2.3. “Scientific excellence” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
5.2.4. Financing and the orientation of research . . . . . . . . . . . . . . . . . . . 229
5.2.5. Prospective opportunities for the research unit . . . . . . . . . . . . . . . . 230
5.2.6. Collective projects? Risky projects? . . . . . . . . . . . . . . . . . . . . . . 233
5.3. Creativity’s place in research . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
5.3.1. Support to creativity? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
5.3.2. But all the same, strong brakes on creativity… . . . . . . . . . . . . . . . . 240
5.3.3. What to do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
5.4. Innovation, a consequence of creativity . . . . . . . . . . . . . . . . . . . . . . . 243
5.4.1. Academic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
5.4.2. Between productions resulting from science and
responsible conscience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
5.4.3. Engagement toward a future focused on innovation? . . . . . . . . . . . . . 251
5.4.4. Caught between two chairs? Between
more than two chairs? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
5.4.5. Innovation as scientific production: is it
born of freedom? What freedom? . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
5.5. What solutions to evoke for additive manufacturing? . . . . . . . . . . . . . . . 257
5.5.1. General framing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
5.5.2. And if the history of additive manufacturing
in France were examined in light of these comments? . . . . . . . . . . . . . . . . 264
5.5.3. A bit of creativity? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
5.6. In the form of a conclusion: a summary
of the author’s point of view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
5.7. Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Acknowledgments
Sincere thanks to 3A, BeAm, 3DCeram, 3D Systems, Fives, Nanoscribe, Poietis,
Prodways, XtreeE, Alex (alias Alexandre Martel, co-founder of 3D Natives.com)
and Laurent Dupont, head of the Lorraine Fab Living Lab® for their effective
cooperation, and particularly for graciously providing certain images.

Prototype part (3DCeram, 2017), reproduction of the Église
de Bonsecours in Nancy (LRGP, 1994) and metallic
part (3A – Applications Additives Avancées, 2017)
Foreword
The evocative expression “3D printing” has been overtaken in everyday speech
by the expression generally preferred by scientists and engineers, “additive
manufacturing”. In both cases, it is a matter of manufacturing objects in successive
layers, and soon every workshop and every school will have a 3D printer and engage
in additive manufacturing. Self-service workshops known as fab-labs already offer
users the possibility to create their own objects. However, the adventure is not over,
as “4D” is coming up over the horizon with materials that evolve over time, not to
mention “bio-printing”, which aims to create organs to be used to repair the living.
Furthermore, the 3D printing of tomorrow, which will be performed without layers,
threatens to make the term “additive manufacturing” obsolete, thereby making it
possible to return to the initial concept of 3D printing. Whatever the case may be,
we are faced with not only a very active and booming world, but also a complex
world that calls on numerous skills in physics, engineering, chemistry of materials
and mechanics with a resolutely multidisciplinary and convergent approach.
To understand the origin of the ideas in additive manufacturing/3D printing,
learn about the current state of what is known and explore the developments to
come, what could be better than to ask one of the inventors of the technology and
one of the first French patent holders in the field, Jean-Claude André, to share his
knowledge with us? This led to the idea of this 3-volume edition that I am pleased to
present; a work that is both erudite and prospective, as its intention is to start at the
genesis of the ideas that led to additive manufacturing to anticipate the impact and
future of still “additive” technologies and, beyond this, to encourage reflection on
the interactions between science and society of today and tomorrow.