3D printing with graphene is one of the next challenges
Graphene is hailed as a wonder material with the potential to revolutionise 3D printing. Scientists and developers are working on printing computers, solar cells, electronics and even cars from graphene. Whilst the realisation of many of these visions is still a long way off, a number of important breakthroughs have been achieved in recent months.
Graphene consists of a single layer of carbon atoms arranged in a hexagonal lattice and is considered the thinnest, strongest and most flexible material in the world. It is also an excellent conductor of heat and electricity.
These properties have captured the imagination of scientists and developers who are working on printing computers, solar cells, electronics and even cars from graphene.
Whilst the realisation of many of these visions is still a long way off – if they are to become a reality at all – a number of important breakthroughs have been achieved in recent months. In September, Graphene 3D Lab filed a patent for the first 3D-printed graphene battery, and at the end of October 2014, the couple who had been working on the technology for five years unveiled the first 3D-printed battery to the public.
The founders of Graphene 3D Lab capitalised on the fact that graphene, in the form of nano-flakes, can be mixed with thermoplastics commonly used in FFF/FDM 3D printers. The company is working on a graphene-based nanocomposite filament that can be used in a standard 3D printer to produce a functioning battery. This would mean that virtually anyone with access to a 3D printer could print their own power source.
So far, there is only a prototype, but it can already generate as much power as a conventional AA battery, which is used in standard devices such as torches and toys. The battery can be printed in almost any shape, meaning it can be integrated into a wide variety of different devices. The company plans to start selling graphene-containing filament in early 2015 and hopes to launch its first multi-material printers in early 2016.
Graphene 3D Lab has also entered into an agreement with Missouri-based company taulman3D to jointly develop a graphene-infused nylon material for use in 3D printers. Experts see great potential for this technology in sensors, small devices and embedded electronics that are set to become part of the Internet of Things.
Whilst graphene-based 3D-printed batteries have attracted a great deal of attention, another scientific breakthrough has caused even more of a stir. Researchers led by Professor Seung Kwon Seol of the Korea Electrotechnology Research Institute (KERI) have described a method for 3D printing pure graphene nanostructures. This is the first time that graphene has been printed on its own, without mixing it with other materials. The research was published in the journal *Advanced Materials* under the title “3D Printing of Reduced Graphene Oxide Nanowires”. The study demonstrates that the method works, but there are still some challenges to overcome. One of these is increasing the yield; another is reducing the size of the extruded material to below 10 nm.
Until now, the recently discovered material graphene has not been available in large quantities. Researchers had only been able to produce small batches of this ‘black gold’ with its miraculous properties. Now, a recently founded company, Cambridge Nanosystems, has secured funding for a new plant capable of producing up to five tonnes of the extremely valuable black powder annually. The plant is due to come on stream in 2015. Cambridge Nanosystems uses a patented system to convert biogas into graphene. The gas can come either from a natural gas pipeline or from exhaust gases.
Once production is up and running, Cambridge Nanosystems plans to be part of the group developing new applications for the material. 3D printing will play a major role in this. According to the British newspaper The Telegraph, the company is in talks with some of the leading aerospace and automotive manufacturers about using graphene in composite materials to produce super-lightweight, indestructible machines that do not rust. Cambridge Nanosystems will provide ideas and develop prototypes, but leave the actual production to others.
FAQ – Frequently Asked Questions
Graphene is a single layer of carbon atoms arranged in a hexagonal lattice. The material is extremely thin, light and flexible, and exhibits high mechanical strength as well as excellent electrical and thermal conductivity.
Possible applications include 3D-printed batteries, sensors, flexible electronics, solar cells and conductive components. Graphene can also be combined with thermoplastics to form nanocomposites and used as a component in 3D printing filaments.
One approach involves mixing graphene nanoplatelets with thermoplastic materials to produce a conductive filament. This filament can be processed in FFF or FDM 3D printers to create battery components in various shapes.
The main challenges include producing larger quantities of material, ensuring consistent quality, scaling up production and achieving cost-effective processing. When printing graphene nanostructures directly, yield and resolution also need to be further improved.
