New 3D Printed Metal is as Small as a Virus and Super Strong
Caltech researchers made a major discovery recently. Caltech’s method allows for the creation of metallic materials that are as small as 150 micrometers (similar to a virus, and therefore invisible to the human eye), with a strength three to five times greater than other materials.
Why is this method of 3D printing so effective? Let’s first discuss the disadvantages of making materials so small. These nanomaterials have a “very messy microstructure” at an atomic scale, which would cause serious defects to larger metal objects.
When operating at the nanoscale, however, there are some differences. A nano-pillar with no defects would fall apart when in contact with another one, but one that is full of “defects,” has a much higher fault tolerance. Wenxin Zhang is the lead author of the paper. According to Zhang, “pores” in the interior of the nano-pillar allow faults to be eliminated almost immediately, instead of weakening entire structure.
What does it all mean? It means, firstly, that physics becomes very weird at a micro-scale. The more technology progresses, the more we’ll find strange rules, like this one. But secondly and more importantly, a lot of very useful things can be created this way, including nano-scale sensors, heat exchangers, and more.
Caltech’s labs use a specific manufacturing process that is not compatible with any 3D printers.
The process is complex and includes building a photosensitive mix that contains a hydrogel, hardening the mixture with a high-powered laser, infusing it with another solution containing nickel ions, baking the mixture, and chemically removing oxygen atoms from the parts. Zhang’s paper contains additional details.