A Process to Use Metal Fine Wire for Metal 3D Printing at Room Temperature

3D printing enables the rapid production of customized prototypes and products. However, metal 3D printing requires large amounts of electrical energy to form products with heat and lasers. Ultrasonic metal wire bonding can be done at room temperature and uses less electrical energy. However, this method is only used in static mode, where the tool remains stationary and can only bond at discrete points. In order for this method to be applicable for 3D printing, the bonding process must become continuous rather than static. Therefore, there is a need for an energy-efficient, continuous 3D metal printing process. Researchers at Arizona State University have created a process to use metal fine wire for 3D printing at room temperature. This process involves the use of ultrasonic power and metal filaments to form solid metal shapes. The process physics have been altered to enable the continuous bonding process necessary for 3D printing. This can result in the high-quality, high-rate production of metal components. Potential Applications 3D printing Metal additive manufacturing Rapid prototyping Aerospace manufacturing Automotive manufacturing Benefits and Advantages Energy efficient - Process takes place at room temperature. Eliminates the need for high heat and laser applications. Wide range of application Compatible with a variety of metals. Rapid prototyping Fast, cost-effective production of models and prototypes during the product development phase. Download Original PDF For more information about the inventor(s) and their research, please see Dr. Keng Hsu's directory webpage