3-D-printing nanocomposites by embedding pre-built microchips and sensors into printed parts

Researchers at the University of Nottingham have pioneered a breakthrough method to rapidly 3-D print fully functional electronic circuits. The circuits, which contain electrically-conductive metallic inks and insulating polymeric inks, can now be produced in a single inkjet printing process where a UV light rapidly solidifies the inks. The breakthrough technique paves the way for the electronics manufacturing industry to produce fully functional components such as 3-D antennae and fully printed sensors from multiple materials including metals and plastics. The new method combines 2-D printed electronics with Additive Manufacturing (AM) or 3-D printing - which is based on layer-by-layer deposition of materials to create 3-D products. This expands the impact of Multifunctional Additive Manufacturing (MFAM), which involves printing multiple materials in a single additive manufacturing system to create components that have broader functionalities.

The breakthrough speeds up the solidification process of the conductive inks to less than a minute per layer. Previously, this process took much longer to be completed using conventional heat sources such as ovens and hot plates, making it impractical when hundreds of layers are needed to form an object. In addition, the production of electronic circuits and devices is limited by current manufacturing methods that restrict both the form and potentially the performance of these systems.

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