Bioinspired Multi-Metal Structures Produced via Direct Ink Writing

Abstract

Bioinspired Multi-Metal Structures (MMSs) combine distinct properties of multiple materials, benefiting from improved properties and providing superior designs. Additive Manufacturing (AM) exhibits enormous advantages in applying different materials and geometries according to the desired functions at specific locations of the structure, having great potential in fabricating multi-materials structures. However, current AM techniques have difficulty manufacturing 3D MMSs without material cross-contamination flexibly and reliably. This study demonstrates a reliable, fast, and flexible direct ink writing method to fabricate 3D MMSs. The in-situ material-switching system enables the deposition of multiple metallic materials across different layers and within the same layer. 3D Fe–Cu MMSs with complex geometries and fine details are fabricated as proof of concept. The microstructures, chemical and phase compositions, and tensile fracture surfaces of the Fe–Cu interfaces indicate a well-bonded interface without cracks, delamination, or material cross-contamination. We envision this novel method making other metallic combinations and even metal-ceramic components. It paves the way for manufacturing 3D MMSs using AM and establishes the possibilities of numerous MMSs applications in engineering fields.