How to 3D Print Multi-Material Structures

Creating parts with multiple materials has been difficult due to traditional manufacturing limitations. Washington State University researchers have explored multi-material additive manufacturing (MM-AM) to overcome these limitations. This guide provides a simplified overview of how to leverage MM-AM for creating parts with enhanced properties and functionalities.

1. Understand the Benefits of MM-AM: MM-AM allows for the creation of parts with region-specific properties, such as hardness, corrosion resistance, and biocompatibility, all within a single component. This eliminates the need for post-fabrication assembly and welding. 
2. Identify Material Combinations: Determine the appropriate material combinations based on the desired properties and application. Consider combining metals, ceramics, and polymers to achieve specific functionalities, such as increased wear resistance or biocompatible coatings. 
3. Select an Appropriate AM Process: Choose an AM process suitable for the selected materials and desired part complexity. Polymeric 3D printing is a good starting point, while metal AM processes are suitable for more demanding applications. 
4. Design for MM-AM: Design the part with specific regions designated for different materials. Consider creating functionally gradient materials (FGM) by gradually transitioning between materials to optimize performance. 
5. Control Material Properties: Manipulate the metal’s properties by adding different phases, such as a secondary metallic phase, to new or pre-existing structures. By controlling the amount of these phases the metal’s properties can additionally be manipulated. 
6. Fabricate the Part: Utilize the selected AM process to build the part layer-by-layer, precisely depositing each material in its designated location. Ensure proper bonding between materials to avoid stress concentrations.