Researchers find a way to heat 3D printer filament using microwaves, enabling fusing circuits inside printed objects — tech supports precise heating down to the width of a human hair

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A team of researchers from Rice University has achieved a new breakthrough in 3D printing that has unlocked the construction of brand-new electronic tech that was previously impossible. As reported by New Atlas, a paper published by the aforementioned team describes a new 3D-printing process using microwaves capable of heating up nanoparticle ink with extreme precision.

This bleeding-edge microwave tech, called “Meta-NFS” or metamaterial-inspired near-field electromagnetic structure, can heat ink in a concentrated zone as small as a human hair. Further still, the microwaves can be programmed to penetrate through an object's outer layer to heat the inside layers without causing damage to the exterior.

Rice researchers redefine what we can build by 3D printing electronics with focused microwaves - YouTube

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This incredible accuracy enables the printer to fuse circuits inside a 3D printed object, something that has been impossible to do with outgoing manufacturing methods, and is a problem that has plagued the industry for a decade. Current manufacturing methods use lasers and furnaces to heat nanoparticles in circuit boards from the outside in. This works for traditional electronic manufacturing, but prevents 3D printers from making specialized electronics that interface with softer materials.

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Meta-NFS also allows 3D printers to use an expanded assortment of materials, including metals, ceramics, and thermoset polymers. Further, the tech also reportedly improves production efficiency through real-time adjustments in microwave power, enabling a Meta-NFS printer to create a print (in one continuous print) without swapping materials.

Meta-NFS's abilities are enabling the creation of new electronic tech that was previously difficult to accomplish with conventional manufacturing. A few of these applications include integration of electronics onto robots with soft skin, implants, and even plants. The researchers showed several examples, including using Meta-NFS to print wireless strain sensors on biocompatible polymers and create devices that can integrate into plants for real-time growth monitoring. This was only possible through Meta-NFS's compatibility with metal and carbon-based materials.

These are just a few of the applications Meta-NFS has in the electronic manufacturing industry. But it is expected that the tech will be a critical part of many groundbreaking technologies moving forward.