A NOVEL COATING METHOD USED TO ENABLE MULTILAYER STRUCTURES WITH MICROSCALE SELECTIVE LASER SINTERING

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Date

2023

Authors

Liao, A.
Behera, D.
Cullinan, M.A.

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University of Texas at Austin

Abstract

The microscale selective laser sintering process (µSLS) is an additive manufacturing technique that enables the creation of metal features with sub-5 µm in-plane resolution. In this process, a layer of metal nanoparticle ink is deposited onto a substrate and positioned beneath an optical subsystem with a nanopositioning stage. Using a digital micromirror device, a laser is spatially modulated to selectively heat up particles in desired regions to cause sintering. The substrate is then moved to a coating station where a new layer of nanoparticle ink is applied atop the sintered features. Initially, the slot-die coating process was adopted as the recoating method for this technique. However, due to challenges with depositing consistent ink thickness across the recoated part and limitations with the minimum layer thickness achievable, a new approach inspired by blade coating has been developed to achieve layer thicknesses of less than 1 µm.

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