Laser-Induced Graphene Enabled Additive Manufacturing of Multifunctional 3D Architectures with Freeform Structures

Area of Science:

• Materials Science
• Additive Manufacturing
• Nanotechnology

Background:

• 3D printing of graphene structures is crucial for smart materials.
• Existing methods like graphene oxide inks have limitations in scalability and 3D form.
• Laser-induced graphene (LIG) offers scalable 1D/2D assembly but struggles with 3D macrostructures.

Purpose of the Study:

• To develop a novel additive manufacturing protocol for 3D graphene structures.
• To overcome the size and shape limitations of current LIG techniques for 3D fabrication.
• To enable binder-free, freeform 3D graphene construction with tunable properties.

Main Methods:

• A new LIG-based additive manufacturing (LIG-AM) protocol using selective laser sintering on polyimide (PI) powder.
• Layer-by-layer irradiation triggering simultaneous particle sintering and graphene conversion.
• Synergistic control of lasing power and powder-feeding thickness to balance processing efficiency and resolution.

Main Results:

• Successful fabrication of bulk 3D graphene with freeform structures without binders, templates, or catalysts.
• Assembly of varied graphene architectures, including identical-section, variable-section, and graphene/PI hybrid structures.
• Demonstration of a LIG-AM printed aircraft-wing section model exhibiting force-sensing, anti-icing/deicing, and microwave shielding/absorption capabilities.

Conclusions:

• The developed LIG-AM protocol is a versatile and scalable method for fabricating complex 3D graphene macrostructures.
• This technique overcomes previous limitations in LIG-based 3D printing, enabling diverse and multifunctional graphene architectures.
• LIG-AM holds significant potential for advanced material applications requiring intricate 3D designs and integrated functionalities.