Additive manufacturing, also called rapid prototyping or 3D printing is a disruptive manufacturing technique with a significant impact in electronics. With 3D printing, bulk objects with circuitry are embedded in the volume of an element or conformally coated on the surface of existing parts, allowing design and manufacturing of smaller and lighter products with fast customisation. The book covers both materials selection and techniques. The scope also covers the research areas of additive manufacturing of passive and active components, sensors, energy storage, bioelectronics and more.

Over the last few decades, a significant interest towards the manufacturing of complex three-dimensional (3D) structures for conceptual models have led to an incredible amount of research and development. 3D structures have been an integral part of physical models or functional end-products and are widely adapted as a miniaturizing technique in manufacturing industries, and in particular, the electronics industry. Advancement in electronics technology has lead to the need for fabricating consumable electronics within a smaller lattice space. To meet the challenge of high functional density integration, Additive Manufacturing (AM) techniques by 3D printing is a promising solution for satisfying the ever-increasing demand for a higher quality product with the ability to customize based on an individual customer needs. AM techniques allows the possibility of developing low cost, multifunctional, compact, lightweight, and miniaturized electronics that can be easily integrated with conventional systems or platforms. In this dissertation, approaches towards utilizing existing AM techniques for fabricating structures that are compatible to carry electrical functionality for RF applications is proposed. The end goal is to develop processes using AM technique as an alternate manufacturing approach to achieve a fully functional electronics system. Specifically, AM holds significant potential in realizing low-loss, high-performance, and light-weight RF components such as transmission lines, waveguides, resonators, filters, and antennas. In order to realize a complete RF system by AM, multiple processes are developed. First, to establish connection for allowing electrical functionality, conductive traces must be patterned on the substrate. Two different metal patterning techniques for selectively patterning conductive traces on the 3D printed substrate is developed. Next, to realize a compact system, a smaller form factor is a necessity and this can be achieved by utilizing the flexibility in the third dimension (z-axis) in designing non-planar RF structures. A number of non-planar RF structures are demonstrated showcasing the advantages of AM in fabricating compact designs. Moreover, for fabricating efficient RF circuits, the losses associated with the printed plastics should be minimized. The currently available printing polymers have high dielectric loss and hence an alternative process that utilizes air as a substrate is developed by using a LEGO-like self-alignment procedure in which the structure is printed in multiple parts and snapped together face to face to integrate the complete structure. Furthermore, a number of active and passive components must be integrated into the printed plastic to achieve a RF system. For this purpose, three different solder-free embedding processes are developed to embedded active devices such as diodes into the 3D printed plastics. Finally, a combination of the above-mentioned processes is utilized to achieve a fully 3D printed electronics system and a potential application of such multi-functional system is demonstrated. Overall, this work demonstrates that 3D printing can be adopted in the fabrication of microwave and millimeter wave high functional density circuits and systems.

The text focuses on discussing the solid-state deformation behavior of materials in additive manufacturing processes. It highlights the process optimization and bonding of different layers during layer-by-layer deposition of different materials in Solid-State. It covers the design, process, and advancement of solid-state additive manufacturing methods. • Covers the fundamentals of materials processing, including the stress–strain–temperature correlation in solid-state processing and manufacturing. • Discusses solid-state additive manufacturing methods, and optimization strategies for the fabrication of additive manufacturing products. • Showcases the mechanisms associated with improvement in mechanical properties of Solid-State additive manufacturing products. • Provides a comprehensive discussion on microstructural stability and homogeneity in mechanical properties. • Presents hybrid solid-state process for fabrication of multilayer components and composite materials. • Provides a detailed review of laser-based post-processing techniques The text focuses on the Solid-State additive manufacturing techniques for the fabrication of industrially relevant products. It gives in-depth information on the fundamental aspects, hybridization of the processes, fabrication of different materials, improvement in product performance, and Internet of Things enabled manufacturing. The text covers crucial topics, including hybrid Solid- State additive manufacturing, cold spray additive manufacturing, online defect detection of products, and post-processing of additively manufactured components. These subjects are significant in advancing additive manufacturing technology and ensuring the quality and efficiency of the produced components. It will serve as an ideal reference text for senior undergraduate and graduate students, and researchers in fields such as mechanical engineering, aerospace engineering, manufacturing engineering, and production engineering. .

This book offers a unique guide to the three-dimensional (3D) printing of metals. It covers various aspects of additive, subtractive, and joining processes used to form three-dimensional parts with applications ranging from prototyping to production. Examining a variety of manufacturing technologies and their ability to produce both prototypes and functional production-quality parts, the individual chapters address metal components and discuss some of the important research challenges associated with the use of these technologies. As well as exploring the latest technologies currently under development, the book features unique sections on electron beam melting technology, material lifting, and the importance this science has in the engineering context. Presenting unique real-life case studies from industry, this book is also the first to offer the perspective of engineers who work in the field of aerospace and transportation systems, and who design components and manufacturing networks. Written by the leading experts in this field at universities and in industry, it provides a comprehensive textbook for students and an invaluable guide for practitioners

Timely summary of state-of-the-art solid-state metal 3D printing technologies, focusing on fundamental processing science and industrial applications Solid-State Metal Additive Manufacturing: Physics, Processes, Mechanical Properties, and Applications provides detailed and in-depth discussion on different solid-state metal additive manufacturing processes and applications, presenting associated methods, mechanisms and models, and unique benefits, as well as a detailed comparison to traditional fusion-based metal additive manufacturing. The text begins with a high-level overview of solid-state metal additive manufacturing with an emphasis on its position within the metal additive manufacturing spectrum and its potential for meeting specific demands in the aerospace, automotive, and defense industries. Next, each of the four categories of solid-state additive technologies—cold spray additive manufacturing, additive friction stir deposition, ultrasonic additive manufacturing, and sintering-based processes—is discussed in depth, reviewing advances in processing science, metallurgical science, and innovative applications. Finally, the future direction of these solid-state processes, especially the material innovation and artificial intelligence aspects, are discussed. Sample topics covered in Solid-State Metal Additive Manufacturing include: Physical processes and bonding mechanisms in impact-induced bonding and microstructures and microstructural evolution in cold sprayed materials Process fundamentals, dynamic microstructure evolution, and potential industrial applications of additive friction stir deposition Microstructural and mechanical characterization and industrial applications of ultrasonic additive manufacturing Principles of solid-state sintering, binder jetting-based metal printing, and sintering-based metal additive manufacturing methods for magnetic materials Critical issues inherent to melting and solidification, such as porosity, high residual stress, cast microstructure, anisotropic mechanical properties, and hot cracking Solid-State Metal Additive Manufacturing is an essential reference on the subject for academic researchers in materials science, mechanical, and biomedicine, as well as professional engineers in various manufacturing industries, especially those involved in building new additive technologies.

Materials and manufacturing are the critical enabler of our technological world. With new materials and advanced manufacturing, new opportunities for advanced application become possible. Additive manufacturing (AM), or three-dimensional (3D) printing, is a relatively new manufacturing process, which relies on building up of parts from raw material. It reduces manufacturing waste, is flexible in part output, and opens new final part form-factors/architectures to be accessible for advanced applications. Light-based AM is well established in its ability to fabricate complex 3D structures whose unique properties exceed or are unfound in natural materials, called metamaterials. These unique 3D structures and other benefits of light-based AM make it of increasing interest for fabrication of functional devices, energy storage, sensors, and actuators among others. However, the available materials compatible with light-based AM, and AM in general, is limited. Specific material and processing limitations, viscosity, light absorption, and their underlying chemistry exclude the vast majority of materials from use in light-based AM. The majority of usable materials are on acrylic, vinyl, and thiol-based organic polymers whereas most functional materials are inorganic and not directly compatible.This dissertation focuses on the development of new materials and processes to allow the light-based AM fabrication of functional materials. This includes graphene energy storage devices, patterned 3D deposition for freeform electronics of multiple materials (conductors, dielectric, magnetic), and high-temperature ceramics for lightweight structural electronics in extreme applications. This dissertation lays the foundation for integrating light-based AM methods to electronic device applications that incorporates conducting and dielectric materials in 3D. Further development can allow advanced antenna, bioelectronics, and structural electronics.

Additive manufacturing (AM) is now being used to produce series components for the most demanding applications. It is a disruptive, if not revolutionary, manufacturing technology. The biggest advantage of this technology is its capacity to make parts with any free form, thus paving the way for free and complex part design. Components and integrated structures with complex designs that would not have been possible just a few years ago can now be made according to various requirements. The net-shape manufacturing capacity of AM allows a considerable saving of materials, conventional thermomechanical processing, and machining processes, making it an environmentally friendly manufacturing technology. This book includes two sections that cover new approaches in AM for biomedical applications and advanced technological solutions.