3D printing using ultrasonic waves

Lithuanian software company Neurotechnology is developing ultrasonic technology that will enable the 3D printing and assembly of almost any type of object using a wide range of different materials and components.

Ultrasonic manipulation is a non-contact material handling method which uses ultrasonic waves to trap and move small particles and components. It has a few key advantages over conventional mechanical handling methods, such as:

• it can be used for manipulating material particles and components with very different mechanical properties and shapes;
• it can deal with a large range of particle and component sizes, from a couple of millimetres down to the submillimetre range;
• it can manipulate very small components while completely avoiding the presence of electrostatic forces; and
• it can manipulate sensitive components without causing any damage.

Because of the non-contact nature of ultrasonic manipulation, even small particles in the submillimetre range and sensitive components can be easily handled without causing any damage, enabling its use in many different prototyping and manufacturing scenarios.

“Ultrasonic manipulation can handle a very large range of different materials, including metals, plastics and even liquids,” said Dr Osvaldas Putkis, research engineer and project lead for Neurotechnology’s Ultrasound Research Group. “Not only can it manipulate material particles, it can also handle components of various shapes. Other non-contact methods, like the ones based on magnetic or electrostatic forces, can’t offer such versatility.”

As a demonstration of the technology, the Ultrasound Research Group created a prototype printer that can assemble a simple printed circuit board (PCB). The prototype employs an array of ultrasonic transducers for the positioning of electronic components on a PCB board. In order to ensure high positioning accuracy, it uses a camera for detecting the position of the PCB and the various electronic components. A laser is used for soldering the elements onto the PCB in a non-contact way, complementing the non-contact component manipulation.

Neurotechnology currently has a patent pending for a 3D printing apparatus and method employing ultrasonic manipulation. The company is now inviting other companies to take part in further development and application of the technology.