Conceptual Design of a Pick-And-Place 3D Nanoprinter for Materials Synthesis

Conceptual Design of a Pick-and-Place 3D Nanoprinter for Materials Synthesis The MIT Faculty has made this article openly available. Please share how this access benefits you. Your story matters. Citation Carlson, Max B. et al. “Conceptual Design of a Pick-and-Place 3D Nanoprinter for Materials Synthesis.” 3D Printing and Additive Manufacturing 2.3 (2015): 123–130. As Published http://dx.doi.org/10.1089/3dp.2015.0023 Publisher Mary Ann Liebert Version Final published version Citable link http://hdl.handle.net/1721.1/105200 Terms of Use Article is made available in accordance with the publisher's policy and may be subject to US copyright law. Please refer to the publisher's site for terms of use. 3D PRINTING AND ADDITIVE MANUFACTURING Volume 2, Number 3, 2015 DOI: 10.1089/3dp.2015.0023 ORIGINAL ARTICLE Conceptual Design of a Pick-and-Place 3D Nanoprinter for Materials Synthesis Max B. Carlson,1 Kayen K. Yau,1 Robert E. Simpson,2 and Michael P. Short1 Abstract The past decade has seen revolutionary advances in three-dimensional (3D) printing and additive manufacturing. However, a technique to create 3D material microstructures of arbitrary complexity has not yet been developed. We present the conceptual design of a 3D material microprinter as a concrete step toward an eventual 3D material nanoprinter. Such a device would enable the use of heterogeneous starting materials with printing resolution on the order of tens of nanometers. By combining a pick-and-place particle transfer method with a custom-built laser sintering optical microscope, the core components of the 3D printer are once again reimagined. This advance moves toward generalized material synthesis as an experimental technique to complement computational materials discovery of materials with unique structures and high interface density, such as 3D nanocomposites, metamaterials, and photonic structures. Introduction mentally synthesized. However, no universal method exists to bring CMD-designed materials into reality. Instead, they In 2014, the U.S. White House published the Materials are built one at a time, with custom techniques and starting Genome Initiative,1,2 a strategic document outlining the materials tailored to each end product. country’s pressing needs for materials science research and In the past, the ability to synthesize material microstructures development. Among the many topics listed of critical in- using Edisonian-based methods outpaced the slower, or previ- terest, one was the creation of a 3D material nanoprinter. This ously nonexistent, abilities to simulate materials on the computer. is because many materials of scientific and technical interest This balance has completely reversed in the past 10–15 years, possess features less than a micron in size, which determine with the ability of CMD vastly outpacing the ability to bring the macroscale response of the material in terms of structural CMD-simulated microstructures into reality. Notable examples integrity, corrosion resistance, deformation resistance, and include the prediction of an insulating, transparent phase of so- other desirable properties. Such a device would have the dium7 and designer nanoparticles with optimized surface prop- ability to print materials and their microstructures, or the erties.8 Now the race is on to physically recreate materials different crystal phases comprising the material, with arbi- predicted by CMD. Of particular interest to fields such as radia- trary heterogeneity and complexity. tion materials science are nanocomposites, as the combination of The current absence of a 3D nanoprinter represents a major materials with a high interface density both blends the macro- obstacle to the rapid realization of many materials developed scale properties of the constituent phases and provides the ability by computational materials discovery (CMD),3 an emerging to remove atomic-scale radiation damage as it is produced.9 area of materials science research. Presently, CMD is in a Notable examples include Nb-Cu nanolayered composites de- unique position where the size of atomistic models has not yet signed by Demkowicz et al.10 that were produced using accu- converged with the typical feature sizes that are feasible to mulated roll bonding. While such work is inherently limited to 1D fabricate. CMD allows the design and simulation of material nanocomposites, increasing the interfacial density by moving to properties that do not exist naturally, from the atomic scale to 3D could further enhance radiation resistance by eliminating or the mesoscale and the macroscale.4 This has led to the design slowing microstructural evolution due to layer coarsening.11 of new alloys,5 superconductors,6 and surprising phases of Similarly, the flurry of research into 2D crystals, such as 7 common compounds, some of which have been experi- graphene and MoS2, promises the possibility to combine 1Department of Nuclear Science and Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts. 2Department of Engineering Product Design, Singapore University of Technology and Design, Singapore, Singapore. ª Max B. Carlson et al. 2015; Published by Mary Ann Liebert, Inc. This Open Access article is distributed under the terms of the Creative Commons License (http://creativecommons.org/licenses/by/4.0), which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly credited. 123 124 CARLSON ET AL. different 2D crystals that are exfoliated from their bulks and demonstrated to create 3D photonic crystals by selective then layered into a new van der Waals (vdW)–bonded artificial creation of localized structural defects.24 Here the throughput 3D heterostructure. The resultant 3D crystals are readily de- is greatly enhanced by using holographic lithography to designed by ab initio atomistic models, but the practical process of termine an overall structure, and two-photon writing to make layering the 2D crystals is difficult to master and painstakingly smaller, localized modifications. Soft lithography, meanwhile, slow.12 It is crucial that this process is automated, and a pick- has been used to create 3D, multilayer microfluidic devices,25 and-place printing technology seems to be a clear solution. while a similar method combined with a 3D sugar printer is The field of metamaterials, or superstructures whose prop- used to create sugar-filled channels that can be dissolved after erties behave differently from their smaller constituents, has fabrication to create microfluidic channels.26 Most recently, led to the creation of entirely new materials, such as terahertz IBM has developed a scanning probe lithography system, magnetic antenna arrays,13 and negative refraction-index which can exceed the electron beam lithography resolution ‘‘cloaking devices.14’’ Many other desirable properties can be limit,27 subtractively creating 3D replicas of objects with single tuned via metamaterial creation, as was recently summarized by nanometer height resolution. Subtractive methods, however, Garcia et al.15 As increasingly complex structures are designed cannot create 3D structures of arbitrary complexity with respect and simulated, our ability to fabricate these structures quickly to both shape and material heterogeneity. loses pace with the CMD aspect of metamaterial design. Were a Additional modern 3D printer improvements include print- way to quickly assemble superstructures of heterogeneous inginliquidmetaldroplets,28 submicron photolithography for building blocks to exist, then the only physical bottleneck would material removal in cellulose and other media,29 3D printing of be the ability to synthesize the building blocks themselves, not nanowalls made from electrospun nanofibers,30 and 3D holo- their optically/electrically/magnetically active superstructure. graphic lithography for near-instantaneous nanostructure fab- In this article, the existing methods of 3D printing are first rication in soft materials.31 Weld-based additive manufacturing reviewed as they apply toward satisfying this missing mate- by gas metal arc welding,32 powder bed sintering,33 and elec- rial synthesis need. Next, a new type of 3D printer is pro- tron beam free-form deposition34 can produce heterogeneous posed, which satisfies all the requirements of a 3D material structures if different filler metals, powder layers, or carrier nanoprinter. Realizations of specific components are then gases are used, respectively. However, many of these tech- demonstrated, while existing obstacles to the realization of niques require large amounts of energy deposition, limiting other components are delineated. Finally, the potential im- their resolution.35 Meanwhile, potential exists for the targeted pact that a 3D material nanoprinter would have on the field of positioning of much smaller, possibly heterogeneous structures CMD with physical synthesis is discussed. onto substrates. The efficacy of this approach has been demonstrated in previous research, where an atomic force micro- scopy (AFM) was used to arrange silicon nanoparticles on a Background: Existing Methods of 3D Printing silicon substrate.36 In addition, IBM recently revealed its mo- The field of 3D printing continues to make leaps and vie, A Boy and His Atom,consistingentirelyofstop-motion bounds, with successive implementations pushing the fronti- freeze-frames of single atoms arranged on a flat substrate,37 ers of resolution and widening the diversity of printing media. demonstrating the ultimate resolution attainable by precise

Load more