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Related Concept Videos

Steel Manufacturing01:26

Steel Manufacturing

730
Steel manufacturing is a multi-stage process that begins by smelting iron ore into cast iron in a blast furnace. This initial stage involves layering iron ore with coke, a type of fuel, and crushed limestone within the furnace. The coke is ignited with a high volume of air, leading to the creation of carbon monoxide, which acts to reduce the iron ore to pure iron.
During this smelting process, limestone plays a crucial role by forming slag. Slag captures impurities within the molten iron, such...
730

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Related Experiment Video

Updated: Aug 14, 2025

Indirect Fabrication of Lattice Metals with Thin Sections Using Centrifugal Casting
08:32

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Published on: May 14, 2016

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A Novel Rapid Manufacturing Process for Metal Lattice Structure.

Bashir Khoda1,2, A M M Nazmul Ahsan3,2

  • 1Department of Mechanical Engineering, The University of Maine, Orono, Maine, USA.

3D Printing and Additive Manufacturing
|January 19, 2023
PubMed
Summary
This summary is machine-generated.

A new Design, Bending, Dip, and Join (DBDJ) process creates small-scale metal lattice structures using wires. This novel additive manufacturing method overcomes limitations and achieves strong, low-density structures.

Keywords:
dippinglattice structuretransient liquid phase bondingwire bending

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Area of Science:

  • Materials Science
  • Manufacturing Engineering
  • Additive Manufacturing

Background:

  • Traditional methods struggle with small-scale metal lattice structures.
  • Existing processes often use powders, sheets, or liquid metals, posing manufacturing challenges.
  • A need exists for a transformative approach to fabricate intricate metallic lattices.

Purpose of the Study:

  • To introduce a novel hierarchical manufacturing process for small-scale metal lattice structures.
  • To demonstrate a holistic approach from design to fabrication using one-dimensional metallic wires.
  • To overcome the limitations of current manufacturing techniques for complex lattice designs.

Main Methods:

  • A four-segment hierarchical process: Design, Bending, Dip, and Join (DBDJ).
  • Utilizing topology-based design for continuous thin rod construction.
  • Additive layer stacking to build three-dimensional lattice structures.
  • Dip-coating for material transfer and transient liquid phase diffusion bonding for node joining.

Main Results:

  • Successful manufacturing of various multiscale lattice structures using the DBDJ process.
  • Achievement of very low relative density unit cells (approximately 3.8%).
  • Compressive tests confirmed no failure at the joining nodes, indicating robust fabrication.

Conclusions:

  • The proposed DBDJ process offers a unique and holistic solution for small-scale metallic lattice structure manufacturing.
  • The use of one-dimensional metallic wires represents a significant advancement over existing methods.
  • The process enables the creation of complex, low-density lattice structures with high joint integrity.