Additive manufacturing of hybrid metal/polymer objects via multiple-material laser powder bed fusion

• Published in: Additive manufacturing Vol. 36; p. 101465
• Main Authors: Chueh, Yuan-Hui, Zhang, Xiaoji, Ke, Jack Chun-Ren, Li, Qian, Wei, Chao, Li, Lin
• Format: Journal Article
• Language: English
• Published: Elsevier B.V 01.12.2020
• Subjects: 3D printing; Additive manufacturing; Laser; Metal; Multiple materials; Polymer; Powder bed fusion; Smartphone housing; Surface roughness; Ultrasonic powder dispensing; Ultrasonic powder dispensing; Powder bed fusion; Laser; Polymer; Surface roughness; Multiple materials; Additive manufacturing; Metal; 3D printing; Smartphone housing
• ISSN: 2214-8604; 2214-7810
• DOI: 10.1016/j.addma.2020.101465

Although multiple-material additive manufacturing has progressed rapidly over the last few years, little progress has been made so far on the additive manufacturing of metal/polymer hybrid components due to significantly different material properties. In this study, we investigated the printing of hybrid metal (Cu10Sn) and polymer (PA11) objects through a proprietary multiple-material laser powder bed fusion (LPBF) system. Powder materials were delivered to the build platform through an ultrasonic vibration-assisted dispensing system. Several 2D Cu10Sn/PA11 structures were printed and demonstrated. The scientific mechanism underlying how the interaction between Cu10Sn and PA11 during laser scanning affected printing quality is discussed. In addition, the roughness of the printed Cu10Sn top surface was improved tenfold with the addition of small amount of PA11 powder. Finally, several 3D components consisting of hybrid stainless steel (SS 316 L), copper (Cu10Sn), and polymer (PA11) including entangling structures were printed and discussed. Potential applications of this technology are discussed.