Smart Lattice Structures with Self-Sensing Functionalities via Hybrid Additive Manufacturing Technology

Area of Science:

• Materials Science
• Manufacturing Engineering
• Additive Manufacturing

Background:

• Lattice structures offer exceptional mechanical properties and low density, leading to wide applications in aerospace, medical, and automotive industries.
• Hybrid Additive Manufacturing (HAM) integrates multiple processes to create advanced materials with enhanced functionalities.
• Developing multifunctional lattice structures requires innovative fabrication techniques that go beyond purely mechanical properties.

Purpose of the Study:

• To propose and demonstrate a novel Hybrid Additive Manufacturing (HAM) technology for fabricating smart metal-coated lattice structures.
• To integrate vat photopolymerization (VPP) 3D printing with electroless plating for creating polymer-metal composites.
• To imbue lattice structures with self-sensing capabilities for mechanical load monitoring.

Main Methods:

• Utilized vat photopolymerization (VPP) to fabricate precise polymer lattice structures.
• Employed electroless plating to deposit metal layers (Ni-P and copper) onto the polymer lattices.
• Characterized the fabricated metal coatings and tested the self-sensing functionality of the composite structures.

Main Results:

• Successfully fabricated metal-coated lattice structures using the proposed HAM technique.
• Achieved deposition of Ni-P and copper layers with specific resistivities (8.2×10⁻⁷ Ω⋅m and 2.0 ×10⁻⁸ Ω⋅m, respectively).
• Demonstrated the force-loading self-sensing functionality of the smart lattice structures.

Conclusions:

• The developed HAM technology effectively combines VPP and electroless plating for multifunctional lattice structures.
• Metal-coated lattice structures exhibit potential as resistive sensors for real-time mechanical load monitoring.
• This approach enables the creation of advanced polymer-metal lattice composites with integrated sensing capabilities.