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World first:
3D printing merges with printed electronics

An additive manufacturing first: Electronic circuitry was printed onto a model of an unmanned aerial vehicle (UAV) wing, which itself was 3D printed. [Photo credit: Optomec & Stratasys]

 

 

 

 

What goes together better than peanut butter and jelly?

Well if you are a design engineer hungry for the future of additive manufacturing, mixing 3D printed materials and printed electronics just might come close.

Stratasys and Optomec announced last week that the companies have successfully completed a joint development project to merge 3D printing and printed electronics to create the world's first fully printed hybrid structure.

This first project, the development of a "smart wing" for an unmanned aerial vehicle (UAV) model complete with functional electronics, really can be considered a huge step forward. It has the potential to change product development in industries including medical device, consumer electronics, automotive, and aerospace.

"Bringing together 3D printing and printed electronic circuitry will be a game-changer for design and manufacturing," says Jeff DeGrange, VP of direct digital manufacturing at Stratasys. "It has the potential to completely streamline production by requiring fewer materials and steps to bring a product to market."

An Optomec Aerosol Jet system was used to print a conformal sensor, antenna, and circuitry directly onto the wing of a UAV model. The wing was 3D printed with the Stratasys Fused Deposition Modeling (FDM) process. The electrical and sensor designs were provided by Aurora Flight Sciences, a supplier of UAVs.

"We envision many potential applications of the Stratasys-Optomec approach for hybrid direct digital manufacturing," says David Kordonowy, who leads Aurora Flight Sciences' Aerostructures Research Group. "The ability to fabricate functional electronics into complex-shaped structures using additive manufacturing can allow UAVs to be built more quickly, with more customization, potentially closer to the field where they're needed. All these benefits can lead to efficient, cost-effective fielded vehicles."

The combination of FDM 3D printing and printed electronics technologies can provide benefits over traditional prototyping, manufacturing, and field repair processes. Performance and functionality of products can be improved in two ways: 3D printers enable lighter-weight mechanical structures, and conformal electronics printed directly onto the structure frees up space for additional payload. In turn, the process has a positive impact on the environment by using fewer materials.

"Manufacturers can implement this hybrid technology in a multitude of applications, not just in aerospace," says Optomec's Ken Vartanian. "This technology can benefit numerous industries by allowing thinner, lighter, fully functional structures that cost less to manufacture."

About the developers
Stratasys is a maker of additive manufacturing machines for prototyping and producing plastic parts. The company markets under the brands uPrint and Dimension 3D Printers and Fortus Production 3D Printers. The company also operates RedEye On Demand, a digital-manufacturing service for prototypes and production parts. Stratasys manufactures 3D printers for Hewlett Packard, which it sells under the brand Designjet3D.

Optomec is a-leading provider of additive manufacturing solutions for high-performance applications in the electronics, solar, medical, and aerospace and defense markets. These systems utilize Optomec's patented Aerosol Jet Printed Electronics technology and LENS powder-metal fabrication technology. The company has a global customer base of more than 100 users that includes many industry-leading manufacturers.

Source: Stratasys

Published April 2011

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