The document discusses advancements in 3D printing with novel materials, particularly focusing on ceramics and graphene, highlighting their processing, performance, and future applications. It presents an agenda covering material discovery, development, and the efficiency of manufacturing processes, alongside an overview of critical material dependencies and environmental considerations. The analysis also includes insights into various additive manufacturing techniques and implications for industries such as aerospace, electronics, and biomedicine.

1. 1
3D Printing with Novel Materials
Production, Processing & Performance
Michael Petch – Black Dog Consulting
Inside 3D Printing Conference, Paris. 26th May 2016
michael@michaelpetch.com
@michaellpetch

2. 2
10
CERAMICS:
FUTURE?
11
GRAPHENE:
WHAT?
03
ABOUT ME
04
MATERIAL
DISCOVERY
.
05
LONG TERM
STRATEGY
06
CERAMICS:
WHAT?
07
CERAMICS:
MATERIALS
14
GRAPHENE:
PROCESSING
15
GRAPHENE:
PERFORMANCE
16
GRAPHENE:
FUTURE?
17
OTHER MATERIALS
agenda
3D PRINTING & NOVEL MATERIALS
08
CERAMICS:
PROCESSING
09
CERAMICS:
PERFORMANCE
12/13
GRAPHITE/GRAPHENE:
PRODUCTION
18
QUESTIONS

3. 3
MICHAEL PETCH
Author, analyst, & consultant.
Image Credit: Gyges 3D

4. 4
Material Discovery & Development
1886
Aluminium
$1,200 / kg
2016
Aluminium
$2 / kg.
2015
US 100%
reliant on
imports for 19
critical
minerals
Image Credits: AP Photo, UT Library, Compound Chem, US Geological Survey.
Smartphones
contain half
elements in
periodic table.
Av. Life = 3
years (Bakker,
2014)

5. 5
“Over the long term, actions to increase resiliency
may include the development of new methods of
extraction, processing, and manufacturing that
promote the efficient use of materials; increased
recovery of materials from waste and scrap; and
research and development of alternative materials
and new product designs to reduce
the demand for limited materials.”
Testimony to Senate Energy and Natural Resources
Committee on May 12, 2015 by Richard Silberglitt,
RAND

6. 6Ceramics: What?
Image Credits: Petr Novak Wikipedia , Engineering Civil, Empa
50% of everything made this year will be made from ceramics (Purnell, 2013)
Post-hard machining incurs up to 80% of the overall manufacturing costs of a ceramic product (Travitzky et al.,
2014)

7. 7
Ceramics: Materials
Ceramics vs Fine / Advanced Ceramics
Chart Data Source: Fine Ceramics World
Ceramic paste
Ceramic powder
Liquid binder (for binder jet)
Photo-curing ceramic composite resin
Preceramic paper
Materials for AM
SiC preceramic paper for
LOM
(Travizky, 2014)
UV curable monomers &
UV photo initiator.
(Schaedler et al., 2016)

8. 8Ceramics: Processing
Image Credits: Laurens van Lieshout, Sandia National Laboratories/Randy Montoya, Heraclitus by Hendrick ter
Brugghen, HRL Laboratories LLC, Schaedler et al., 2016.
AM techniques for working with ceramics.
1 Foil supply. 2 Heated roller. 3
Laser beam. 4. Scanning prism. 5
Laser unit. 6 Layers. 7 Moving
platform. 8 Waste.
Laminated Object
Manufacturing with
preceramic paper
Robocasting with
hydrogels & ceramic
slurries
UV Stereolithography
with silicon oxycarbide

9. 9Ceramics: Performance
Image Credits: Özkol et al., 2012, Feilden et al., 2016, Schaedler et al., 2016, HRL Laboratories/Dan Little, General
Electric GE9X , Joannopoulos et al., 2011.
Biomedical, aerospace, electronics & semiconductors.
Complex geometry, low porosity, high strength & thermal resistance.

10. 10Ceramics: Future?
Image Credits: NASA, Carpenter, J.

11. 11Graphene: What?
Image Credits: Nobel Museum, Alexander AIUS, Tian et al. 2006, Novoselov & Geim: Roadmap for Graphene
2015.
A two-dimensional, atomic scale, monolayer, polyaromatic hydrocarbon.
A single sheet of graphite.

12. 12
Graphite: Production
Graphite demand to increase by 200% within 4
years.*
Image Credit: USGS, 2016, *Benchmark Mineral Intelligence
China: 72% installed capacity worldwide, 55% total
flake graphite production.
3 ton natural flake
graphite
=
1 ton spheroidal graphite
800 million tons
=
World recoverable
graphite

13. 13
Graphene: Production
Graphite must be intercalated to render it
susceptible to exfoliation.
Image Credit: Garg et al., 2014, Ben Mills
Sulfuric acid
Potassium
permangate
Sodium nitrate
Potassium
persulfate
Phosphorus
pentoxide
1. Oxidation of graphite
Brodie Method (1859)
Hummers Method (1958)
Modified Hummers (Kovtyukhova, 1999 &
Tour, 2010)
2. Exfoliation 3. Reduction 4. Dispersal or
Nanocomposite

14. 14Graphene: Processing
Image Credits: Griffiths, 2015, Dul et al. 2016, Jabari & Toyserkani, 2015.
AM & fabrication techniques for working with graphene.
“Gbot” UV curable 3D
printable graphene ink
Extrusion with
thermoplastic polymer
nanocomposite (PNG)
Aerosol jet printing for
graphene interconnects

15. 15Graphene: Performance
Image Credits: Zhu et al., 2015, Zhu et al., 2016, Hersam et al., 2015
Super capacitors, electronic & biomedical applications

16. 16Graphene: Future?
Image Credits: Nokia, Volvo, Columbia University, Pacific Water

17. 17Other Materials & Applications
Image Credits: Molybdenum, John Rogers, Wuhan National Laboratory for Optoelectronics, Drexler & Pamlin,
2013

18. 18
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