Novel solution: Tey’s 3D metal printer uses a proprietary formulation to print articles from stainless steel, alumina, copper and silicone without the need for high-energy enclosures.
Researchers at the Universiti Tunku Abdul Rahman (UTAR) Faculty of Engineering and Science will soon release a three-dimensional (3D) metal printer that is cheaper, smaller, and easier to use compared to what’s available in the market today.
The novel innovation, due to its compact size, will take up less floor space and cost only a third of the price of 3D metal printers in the market, said UTAR mechanical and materials engineering assistant professor Dr Tey Jing Yuen.
Dubbed Me+ (material extrusion plus), the UTAR project is a collaboration with Solid Labs Sdn Bhd, which Tey co-founded in 2016 with Dr Bryan Cheong, a local chemical solutions entrepreneur.
Unlike high-energy cost printers that require the mixing of a dry powder with lasers in an enclosed environment, Me+ mixes a slurry of viscous liquid using a proprietary binder solution that can be done at room temperature – a method that results in much lower energy use.
More sustainable
Generally, an object or an article can be manufactured in two ways: subtractive manufacturing and additive manufacturing (AM).
In subtractive manufacturing, layers are “subtracted” from a solid block of material through processes such as lathe, milling and wire cut.
Introduced in the late 1980s, AM, popularly known as 3D printing, is the opposite. Feedstock of build material is deposited through a nozzle and “added” layer by layer using different printing methods.
Historically, 3D metal printing utilises three principal techniques: binder jetting, powder bed fusion and directed energy deposition. Powder bed fusion, the most prevalent, employs sophisticated lasers to melt and mould metal, making it ideal for crafting intricate parts with precise details, Tey explained.
This method, however, is costly and there are significant safety concerns due to the use of intense lasers. The method requires an isolated environment equipped with a cooling mechanism to manage the hazardous metal powder. The metal powder used in this process must be handled with strict care, and extensive cleaning and finishing are required in the post-printing stage.
“Not all of the powder can be recycled, leading to increased costs and unit manufacturing expenses. These unfavourable factors have limited its commercialisation, confining its application to specialised sectors like aerospace, automotive and medical industries,” Tey said, adding that the patent for Me+, which promises a more sustainable and efficient approach to metal printing, has been filed in Malaysia, the United States, Europe, China, Indonesia, Japan, Korea, Singapore, Thailand and India.
Cheaper alternative
As similar machines could cost upwards of US$300,000 (RM1.4mil), Tey said his team hopes to make 3D metal printing accessible to more Malaysian companies.
The project, he added, is aligned with the National Policy on Industry 4.0 (Industry4WRD), which is aimed at improving product performances through smart manufacturing, and transforming the manufacturing sector and related services in Malaysia through Industry 4.0 applications and technologies.
AM has been designated as one of the 11 pillars of Industry 4.0 outlined under this national strategy.
As a researcher, Tey said he found that prototyping new parts for various industrial purposes is a cost-prohibitive venture for many smaller companies in Malaysia.
For instance, heat treatment for prototyping at the parts fabrication stage in Malaysia is more expensive than outsourcing the work to Japan and shipping it back.
“In fact, Japan can assure much better quality whereas the parts fabrication here needs a few trials to get it right.
“It gave me an impetus to find a solution so that companies don’t have to fork out so much money to do machining,” he said.
Greater efficiency
While conventional fabrication to prototype a part can take two to three weeks, Tey hopes Me+ will be able to shorten the period to three days.
“It only takes one person to order the material and program the software to do it,” he said, adding that Me+ is compatible with various materials such as silicone, ceramic or metal.
“To date, we have successfully developed printed articles from stainless steel, alumina, copper and silicone print materials on a single platform.
“What sets this method apart is its potential to significantly reduce capital expenditure and provide a cost-effective solution for the end user.
“It operates with a slurry paste composed of binder and metal powder, and functions at ambient temperatures.
“Once printed, the components undergo a conventional thermal treatment, including thermal debinding and sintering, to prepare them for use.
“With zero powder material wastage, there is also no tedious cleanup,” he said in an interview at the UTAR Sungai Long campus.
According to Tey, 3D printing has taken off in Malaysia but metal printing has not caught on due to costs, infrastructure, energy requirements and the steep learning curve involved.
“Our lab is planning to incorporate artificial intelligence to monitor the printing process.
“This will definitely optimise the performance of the 3D printing object and help to generate a quality control report,” he added.
