Additive Manufacturing of Metals

In this research theme, we develop novel recyclable metal-infused polymeric feedstocks and filaments compatible with low-cost material extrusion 3D-printing (sinter-based metal 3D printing) by using environmentally friendly extracted recycled metal powders (fillers) and recyclable bio-based polymers (matrix), and investigate subsequent post-processing to produce functional fully metal parts. In this method, in order to get a fully metallic part, a high metal concentration needs to be incorporated into the polymer to make composite filaments and 3D printed parts, followed by debinding and sintering post-processes to burn out the polymer and get fully dense metal components. To this end, pre-process, in-process, and post-process properties (e.g., rheology, microstructure, thermal, mechanical, and physicochemical) of metal composition are investigated and evaluated using advanced characterization techniques, both experimentally and theoretically, to avoid nozzle clogging and produce high-performance parts. The outcomes help to prevent the depletion of Canada’s rich natural resources by using environmentally extracted recycled metal powders and bio-based polymers to develop novel metallic feedstock for low-cost metal 3D printing. The carbon cycle for biopolymers shows a decreased carbon footprint compared to fossil fuel-derived polymers, which reduces greenhouse gas emissions.