3d‐painted solid oxide fuel cells: a new approach to...
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3D‐PaintedSolidOxideFuelCells:ANewApproachtoFunctionalMulti‐CeramicDeviceFabrication
NicholasR.Geisendorfer1,3HongqianWang1;ZhanGao,PhD1*;AdamE.Jakus1,3*,PhDProf.ScottA.Barnett1,PhD;Prof.RamilleN.Shah,PhD1,2,3
NorthwesternUniversity‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
1MaterialsScienceandEngineering2TransplantSurgery
3SimpsonQuerrey InstituteforBioNanotechnology*FormerAffiliation
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Evanston,IL
October3rd,2017
Let’s categorize “Additive Manufacturing” and “3D‐Printing”(See ASTM F42)
Powder-Bed
High-power energy beam
Pratt and Whitney
Biomet
(not for metals)
Primarily associated with metals
“Rapid Prototyping”
Primarily associated with thermoplastics
“Additive Manufacturing” and “3D‐Printing”
3D‐PAINTING
(See ASTM F42)
Where do ceramic materials fall?
The Shah Tissue Engineering and Additive Manufacturing LaboratoryDefining “3D‐Printability” and creating and developing new, 3D‐printable materials
for any and all applications.
Science Translational Medicine, 2016.(Cover)
In Review
Advanced Functional Materials 2017. (Cover)
Scientific Reports 2017.
Adv. Eng. Mat. 2017.
JBMR‐A, 2017.
JBMR‐A, 2017.
Acta Astronautica. (In Rev iew)
Particle‐Laden Inks“3D‐Painting”
Organic Solvent‐BasedPrimarily Rigid ParticlesMulti‐Mat. Compatible
Can’t Encapsulate Live Cells
Well beyond biological and medical applications
Hydrogel/Cell‐Based Inks“PEGX Bioinks”
Aqueous‐Based, Primarily WaterHydrophilic
Multi‐Mat. CompatibleCan Encapsulate Live Cells (Bioprinting)
3D-PAINTING: A comprehensive, Materials-Centric approach to 3D-printing & Additive manufacturing
A selection of more than 300 distinct 3D-Inks developed by the Shah TEAM Lab(...and can be mixed and modified ad infinitum)
Not merely different colors… Completely different materials!
“3D-Paints” contain the same major components as household paints, but dry much quicker!
LSM
Room‐temperatureextrusion
Deposition rates up to 150 mm/s*
* Maximum speed of our hardware, not material l imited.
Objects can be handled immediately
One to thousands of layers
100 µm to 2 mm** fiber diameter
** Maximum diameter tested
No powder beds or resin bathsNo Support materials required
No curing or post‐reactions to stabilize structures
Real Time
16x Speed
Fe2O3
Standard DIW and Composite Filament FDM
TEAM 3D-Paints
3D‐Paints are composed primarily of the functional particle/powder rather than of non‐functional
polymer
Solidify via rapid evaporation of solvent
upon extrusion
3D-Paints
A Selection of70 vol.% Particle Inks Long shelf-life
(Printable for at least 24 months after synthesis)
Inks do not settle-out over time
No need to re-wet. Remain flexible for at least 4 years.
Flexible(roll)
Fold
Fold + Cut
Fold + Cut + Fuse
Efficient and Scalable Solid Oxide Fuel Cell Fabrication Via 3D-Painting
US Patent Application 15/212,534“Efficient and Scalable Solid Oxide Fuel Cell Fabrication v ia Extrusion-based 3D-Printing of Liquid Inks” Manuscript in Preparation
O2H2
Load
Anode Electrolyte Cathode
H2O
e- flow
H2 (g) + ½ O2 (g) H2O (g) + e- at high temperature
Heavy Fasteners
https://fuelcellsworks.com
Fuel cells aren’t economically viable for widespread adoption…yet
Farandos et al. Electrochimica Acta (2016)
Inkjet Binding “Original and Proprietary” (Inkjet Binding)
Huang, et al. Advanced Materials Technologies (2017)
Binder Jetting
Manogharan, et al. Journal of Materials (2015)
Multi-step firing procedure
Size and Geometry LimitationsSize and Geometry LimitationsGeometry Limitations
Only demonstrated electrolyte materialsLittle microstructural control
Require a versatile and scalable process to fabricate monolithic multi-ceramic fuel cell stacks
without the need for labor-intensive assembly and non-
functional, structural components…
3D‐PAINTINGApply 3D-Painting to SOFC manufacturing!
8x speed
YSZ (w/ Fe2O3)
LSM
No drying time required.
Objects can be handled immediately after being created.
NiO-YSZ
23
Not a “push-button” technique, requires controlling >15 independent parameters(i.e. applied pressure, linear speed, needle offset etc. )
Anode Side Cathode Side
YSZ LSMNiO-YSZ
3D-printed architecture maintained and desired microstructure achieved!
Current-Voltage Measurement Impedance Spectroscopy
Relatively poor performance…for now.
> 1 V desired
< 1 Ω desired
Good performance, but more cumbersome fabrication and assembly…not scalable!
Plots courtesy of Dr. Zhan Gao
Schematic courtesy of Dr. Adam Jakus
Provides additional versatility in fabrication!
Ink system can be utilized to create thin films as well as 3D-structures
Shrinkage manageable by tailoring ink composition.
Ink versatility provides many ‘knobs to turn’ for control
The FUTURE
Dip Coating
3D-Painting
Ink Casting
The Present
Where are we going?
Prof. Ramille N. Shah, PhD
CollaboratorsProf. Scott A. Barnett, PhDHongqian WangZhan Gao, PhD
[email protected]‐[email protected]
Adam Jakus, PhDChristoph Kenel, Dr. sc.Xin Li, PhDShannon TaylorPhillip LewisJimmy SuEmma GargusKelly Parker
This work is supported by a NASA Space Technology
Research Fellowship