Abstract
Additive manufacturing (AM) is now identified as a powerful bundle of fabrication techniques. Limitations were identified to be mostly related to the availability of reformulated materials compatible with existing AM technologies. What if we were able to dynamically generate sacrificial molds with unlimited architectures and material composition? We have developed such a process, called Dynamic Molding in partially ordered powder system and demonstrated its capacity to produce highly complex objects with 100 µm resolution, without any building plate or support structures. The Dynamic Molding compatible materials were shown to be almost infinite, from low to high viscosity, from thermoplastic to elastomers. This process enables to build unexpected composite objects made up of injection material and powder grains inherited from the dynamic mold. This feature opens the path to a complete new field of research and applications. • A new additive manufacturing method was developed which fill the gap between 3D printing and molding. • The new technique was named Dynamic Molding Deposition. • The method was shown to be free-form and capable of handling a large range of material viscosity. • The technique was shown to permit the production of unexpected composite objects with interesting mechanical properties.
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