Fabrisonic has an Ultrasonic Additive Manufacturing (UAM) that combines ultrasonic welding and CNC machining. The UAM additive manufacturing process is very suitable for manufacturing large metal parts with embedded sensors and internal structures, but it is difficult to manufacture metal parts with complex geometric structures.
Fabrisonic has launched a project that combines UAM with powder bed selective laser melting (L-PBF) technology suitable for manufacturing complex structures, using the advantages of two different additive manufacturing technologies to manufacture metal parts embedded in sensors.
UAM and LPBF process combined with 3D printed metal parts finished product: metal parts with integrated electronic functions
UAM Additive Manufacturing
The principle of the UAM process is to apply ultrasonic waves with a frequency of up to 20,000 Hz to the metal sheet, and use the oscillation energy of the ultrasonic to rub the two surfaces to be welded to form a fusion between molecular layers, and then weld the metal sheet layer by layer using the same principle. , And at the same time through mechanical processing to achieve fine three-dimensional shapes, thereby forming a solid metal object.
With Fabrisonic’s method, multiple metal materials, such as aluminum, copper, stainless steel, and titanium alloys, can be “printed” at the same time. Since the working temperature of ultrasonic welding is very low, unnecessary metallographic changes will not occur. This process can use rolled aluminum or copper metal foils to produce metal parts with complex internal channels. The ultrasonic additive manufacturing process can be used to fully embed wires, tapes, foils, and so-called “smart materials” such as sensors, electronic circuits, and actuators into dense metal structures without causing any damage, thus providing a good basis for electronic devices. Design brings new possibilities.
Responding to more complex manufacturing needs
Fabrisonic`s customers are looking for a way to manufacture complex stainless steel parts embedded with sensors. Specific requirements include:
• Manufacturing stainless steel parts with complex structures • Transitional structures with different metal materials • Embedding sensors in this part It is not difficult to see from the principle of the UAM process that the process is suitable for manufacturing multiple metals, embedded sensors and internal structures Of large components. However, due to the large force required to form the bond, the UAM process is not suitable for the fine and complex structural parts required by its customers.
Fabrisonic’s solution is to combine UAM and LPBF two metal additive manufacturing technologies, and continue to complete the manufacture of a variety of metal materials and embedded sensors on the basis of LPBF 3D printed parts manufactured by partners through the UAM process.
In this process, LPBF 3D printed parts are first fixed by fixtures. This is a very critical step. If the fixing is not in place, the vibration generated in the subsequent processing will cause the substrate to shift. The next step is to mill the top of the LPBF 3D printed part with Fabrisonic equipment to obtain a flat surface for subsequent ultrasonic additive manufacturing. In the subsequent ultrasonic additive manufacturing step, Fabrisonic’s equipment prints aluminum and copper sheets layer by layer on the top surface of the part.
When a variety of metal materials are manufactured to the specified height, milling will begin to process the grooves needed for embedding the sensor. After the sensor is embedded in the groove, the additive manufacturing of copper and aluminum materials is continued, so that the sensor is encapsulated in metal parts, and the sensor is sealed and protected by the metal structure of ultrasonic consolidation layer by layer. In the end, the final shape of the metal part is processed by milling.
The advantage of this hybrid manufacturing method is that the sensor can be placed at the exact location where information needs to be collected, the accuracy of sensor readings can be improved, and the metal seal will extend the life of the sensor.
Fabrisonic said that this case is just one of the applications where UAM is combined with other metal additive manufacturing technologies. As Fabrisonic gains more application opportunities, this technology will continue to develop, achieving the complementary advantages of other additive manufacturing technologies and UAM additive manufacturing technologies.
Two additive manufacturing processes for metal electronic devices
The ultrasonic additive manufacturing process has been used in the research and development of metal electronic devices in rockets. Fabrisonic has signed a contract with the rocket test stand of the Stennis Space Center of the National Aeronautics and Space Administration (NASA) to use UAM additive manufacturing technology to manufacture fuel pipeline parts with embedded sensors. Its role is to improve collection from fuel pipelines. The fidelity of the data.
Sensor pipe made by Fabrisonic
NASA hopes to collect data from the rocket’s cryogenic fuel pipes to better understand the engine’s operating conditions. Therefore, it is necessary to collect data on the internal pressure and temperature gradient of the fuel pipe closer to the test item. NASA usually uses elbows and ports to install sensors on the outside of the pipeline. Although this can transmit a certain amount of data, it is usually limited. NASA has also conducted experiments by placing the sensor directly in the flow path using the through-tube in the existing pipeline, but this will interrupt the fuel flow and create uncertainty in the measurement range.
Fabrisonic’s UAM additive manufacturing technology can integrate the sensor into the pipe wall, thus overcoming the challenges encountered by NASA. Fabrison embeds a set of fiber optic sensors in a position in the pipe wall, which can more clearly show the thermal gradient and pressure gradient in the pipe. In order to reduce costs, only a portion of the pipes are additively manufactured. The manufacturing team created a connection tape embedded with the fiber sensor in the flat part of the existing pipe, and cut a small groove for each fiber. After inserting the fiber, other metal materials are printed on the connecting belt, and then the excess material is removed by mechanical processing.
The UAM process has a relatively low temperature environment, in which electronic components such as wires, tapes, foils, sensors, and electronic circuits are embedded in metal parts without causing damage to the embedded electronic devices. In this way, the sensor can be embedded in a more destructive environment.
Although powder bed selective laser melting 3D printing technology is more suitable for manufacturing metal parts with complex structures, the high temperature generated during the metal laser melting process can easily cause damage to the electronic components embedded in it. The metal parts embedded in the sensor can be directly manufactured by this technology. Higher difficulty. Fabrisonic combines the ability of UAM technology to manufacture a variety of metal materials and embedded electronic components with the ability of LPBF technology to manufacture complex structures, which may bring new possibilities for the manufacture of complex and conformal metal electronic devices.
Metal 3D printed antenna with embedded electronics.
Engineering services company Etteplan has previously disclosed a metal 3D printed antenna that integrates an integrated circuit with a sensor. This antenna is realized through LPBF 3D printing technology. Etteplan stated that it has overcome the challenge of manufacturing metal parts of integrated electronic components with this technology, and can successfully keep electronic products in good working condition.