Additive Manufacturing for Chemical Sciences and Engineering

Description

This book is tailored designed for both researchers as well as academics teaching or introducing Advanced Manufacturing course to their classrooms. It presents the current state of research in this field of research and major challenges identified so far, for the integration of additive manufacturing into chemical processes. Unique capability of transforming materials into functional devices with specific geometry using the emerging additive manufacturing technologies has stimulated significant interest in biology, engineering and materials science, to provide custom-made designs for tailored applications. However, the applications of this emerging technology in the field of chemical sciences and engineering have started very recently. Therefore, the major focus of this book is to introduce the basic principles of additive manufacturing practices as well as advent into conventional chemical processes and various unit operations. The potential advantage of introducing these additive manufacturing technologies has the potential to scale down large scale chemical processes into small scale, which offers several advantages including lower foot print, waste reduction and efficient heat integration as well as distributed chemical manufacturing. Preface Contents About the Editors 1 An Introduction to the World of Additive Manufacturing 1.1 Background to Additive Manufacturing 1.2 Standardization of Additive Manufacturing Technologies 1.3 Additive Manufacturing—Features and Characteristics 1.4 Additive Manufacturing in Chemical Sciences and Engineering 1.5 Summary 1.6 Test Your Knowledge References 2 History and Evolution of Additive Manufacturing 2.1 Introduction 2.2 The Beginning 2.3 Standardization of AM Technologies 2.4 Advance of AM into Modern Technological Applications 2.5 Four-Dimensional Printing 2.6 Impact of AM on Industries 2.7 Customization 2.8 Summary 2.9 Test Your Knowledge References 3 Material Extrusion and Vat Photopolymerization—Principles, Opportunities and Challenges 3.1 Introduction 3.2 Material Extrusion Additive Manufacturing 3.2.1 MEX Process Variants 3.3 Fused Deposition Modelling (FDM) 3.3.1 FDM Operating Principles 3.3.2 FDM Materials 3.3.3 Process Parameters 3.3.4 Challenges and Outlook 3.4 Vat Photopolymerization (VP) 3.4.1 Vat Photopolymerization—Operating Principles 3.4.2 Photopolymers 3.4.3 Vat Polymerization Parameters and Applications 3.4.4 Vat Photopolymerization–Challenges and Outlook 3.5 Test Your Knowledge References 4 Laser Powder Bed Fusion—Principles, Challenges, and Opportunities 4.1 Additive Manufacturing—General Benefits 4.1.1 Laser Powder Bed Fusion—Process Workflow 4.1.2 Laser Powder Bed Fusion—Influential Parameters 4.1.3 Laser Powder Bed Fusion—Examples Application 4.2 Conclusions and Outlook 4.3 Test Your Knowledge References 5 Robocasting—Printing Ceramics into Functional Materials 5.1 Background—Ceramics Printing 5.2 Principles of Robocasting and Type of Materials 5.2.1 Paste Formulation 5.2.2 Inter-particle Interactions 5.2.3 Role of Water (as a Solvent) 5.2.4 Effect of Viscosity 5.2.5 Effect of Yield Stress 5.3 Post-processing 5.3.1 Drying 5.3.2 Burn-out and Sintering 5.4 Materials Suitable for Ceramic Printing 5.4.1 Robocasting Printed Structures as Functional Ceramic Structures 5.4.2 Current Progress in Multi-ceramic Material Printing 5.4.3 Printing Ceramic Materials into Complex Shapes 5.5 Challenges and Outlook 5.6 Test Your Knowledge References 6 Surface Modification of Additively Manufactured Materials: Adding Functionality as Fourth Dimension 6.1 Background 6.2 Challenges in Functionalization of AM Printed Surfaces 6.3 Post-processing Physical Techniques 6.4 Surface Chemical Functionalization of AM Printed Surfaces 6.4.1 Direct Surface Functionalization 6.4.2 Electrochemical Functionalization 6.4.3 Chemical Modification Procedures 6.4.4 Surface Initiated Polymerization 6.5 Summary 6.6 Test Your Knowledge References 7 Emerging Technological Applications of Additive Manufacturing 7.1 Introduction 7.2 Applications of Additively Manufactured Constructs 7.2.1 Surface Sensitive Applications 7.2.2 Bulk Sensitive Applications 7.3 Summary and Outlook 7.4 Test Your Knowledge References 8 Additive Manufacturing as the Future of Green Chemical Engineering 8.1 Need for Integration of Additive Manufacturing with Chemical Engineering 8.1.1 The Rise of Digitally Controlled Manufacturing 8.1.2 Industry 4.0 and Smart Manufacturing 8.1.3 Process Intensification 8.2 Micro Reaction Technology 8.2.1 Microreactors 8.2.2 Modelling and Simulation in Microreactor Design 8.2.3 Equation Based Generalized Reactor Modelling 8.2.4 Critical Elements in Microreactor Design 8.3 Additive Manufacturing of Micro Reactors 8.3.1 Fused Deposition Modelling for Microreactors 8.3.2 Direct Ink Writing or Robocasting for Microreactors 8.3.3 Stereolithography for Microreactors 8.3.4 Selective Laser Sintering for Microreactors 8.3.5 Selective Laser Melting for Microreactors 8.4 Additive Manufacturing for Green Hydrogen 8.5 Summary and Outlook 8.6 Test Your Knowledge References Appendix Answers to Questions