The Liquid Metal Jet Printing (LMJP) laboratory is developing a revolutionary process technology in additive solid freeform manufacturing process. It can build mechanical parts and electronic interconnects in an additive manner. Unlike spray forming, LMJP is similar to ink jet printing where every individual molten droplet is controlled and printed to specific location. By changing the orifice size, the system will dispense molten spheres of metal with diameters from 100 to 1000 microns.
Current research work is focused on development of an aluminum printing device for rapid prototyping of near net shaped mechanical parts. Previous research work has included metal ball generation and capture, solder masks, and jetting copper for printing circuits.
The LMJ Laboratory at The University of Texas at Arlington is one of only four liquid metal jet research laboratories in the U.S. Our innovative high temperature droplet generator technology is a manufacturing process breakthrough allowing higher melting point metals such as copper, aluminum and solders to be printed (U.S. Patents 5,560,543, "Heat Resistant Broad - Bandwidth Liquid Droplet Generators" and 5,810,988, "Apparatus and Method for generation of micro spheres of Metals"). The metal jet laboratory research team is possibly the only university research laboratory in the world capable of developing high speed, multiple print head jetting for metal printing applications.
This project allows the ARRI LMJP laboratory to expand from its current single jet capability to a faster multi-jet system. We will develop a "proof of concept high speed jet system" to prove that a production system is possible using array of jets. The deliverables are test coupons that are produced using multiple jet heads.
Insitu Formation of Ceramic Metal Matrix Composites using Liquid Metal Jet Printing :
LMJP team members are performing research in the development of a ceramic metal hybrid. The LMJP process is being used to form aluminum structures which are reinforced with high wear resistance ceramic particles.
Designed and fabricated high speed solder, copper, and aluminum jet systems printing capability and direct CAD/CAM interface
Producing solder test coupons for PWB
Designed and fabricated a successful copper jetting system for ball generation
Apparatus and methods for making uniformly-sized and predictably-spaced droplets or solid microspheres from high-temperature or other liquids. Liquid droplet generators having electromechanical driving elements are coupled to a power supply to apply pulsed excitation forces through a wall of a delivery tube to a liquid, e.g., a liquid metal, epoxy, or polymer. The excitation forces generated by the driver induce capillary vibrations in the liquid within the delivery tube, which breaks the stream into substantially uniformly-sized liquid droplets shortly after leaving the orifice. Droplets may be produced in a uniformly-spaced series, or individually on demand in response to a single burst of force from the driving element. If solid microspheres are desired, the trajectory of the emitted droplets is determined to permit the solidification prior to catching or collecting the microspheres. Solidification of the spherical drops may be accomplished by freezing, evaporation, or chemical reaction due to heat transfer, material transfer, or chemical reaction as the droplets traverse a controlled environment chamber. To permit collection of the microspheres with controlled material properties and without deforming or otherwise changing either the sphericity or surface quality, the flight path environment is controlled to bring the drops to a very low speed prior to collection of the solidified microspheres.
Apparatus and methods for making uniformly-sized and predictably-spaced droplets from high-temperature liquids. Liquid droplet generators having electromechanical driving elements are coupled to a power supply to apply pulsed excitation forces through a wall of a delivery tube to a high-temperature liquid, e.g., a liquid metal, epoxy, or polymer. The excitation forces generated by the driver induce capillary vibrations in the liquid within the delivery tube. Liquid jet streams having capillary vibrations when exiting an orifice break up into groups of substantially uniformly-sized liquid droplets shortly after leaving the orifice. Droplets may be produced in a uniformly-spaced series, or individually on demand in response to a single burst of force from the driving element. A heat source is also thermally coupled to the delivery tube to maintain the liquid in a high-temperature state. Embodiments using heat-sensitive elements thermally insulate those elements from the wall of the heated delivery tube and may also actively cool the elements by one or more heat exchangers. A magnetohydrodynamic embodiment couples a magnetic field, having spaced points of maximum intensity, to a fluid stream exiting an orifice, causing the stream to break into droplets in response to the periodic magnetic field.
ARRI is an interdisciplinary unit of the College of Engineering
focusing on world class R&D with commercializable applications.
Mission
Our
mission is to generate and apply disruptively innovative knowledge,
advanced industrial technology and community services for purposes of
economic growth, national security and quality of life enhancement.
Vision
Our
vision is global leadership in the emerging discipline of
Microengineering. This is accomplished by augmenting basic and applied
R&D efforts with a comprehensive set of additional programs that
include education, service, extension, pilot production and
commercialization.
Technology Focus
The
second half of the information revolution will be driven by the
application of smart micromachines that can emulate human functions
such as perception, cognition, motion and communication. These are
integrated systems of micro sensors, processors and actuators that
interact with the environment, among themselves, and with humans. Thus,
they provide an interface between the information world and the
physical world. A key research challenge is the development of
manufacturing processes to enable the commercialization of inexpensive,
possibly disposable micromachines.
Economic Development
The
Institute will be a beacon of economic growth and a world leader in the
commercialization of smart micromachines by amalgamating globally
competitive research, world class micromanufacturing technology,
sophisticated market awareness, state-of-the-art facilities, and
intimate ties to industry.
Culture
The
culture at ARRI is goal driven and outcome oriented. Students work in
interdisciplinary teams and are given ample opportunities to become
proficient at analysis, computation, experimentation and
entrepreneurship.
Research Program
The research program consists of three interrelated layers:
Fundamental issues in robotics and microtechnology.
Technological issues in micro and nano scale manufacturing
Engineered systems for complex applications.
Technology Platforms
Technology
platforms are used to demonstrate and evaluate new capabilities,
concepts and applications. These platforms provide: (i) research
continuity by capturing and preserving intellectual residuals, (ii) a
common market pull for realistically complex applications, and (iii)
focal points around which interdisciplinary work can be continuously
integrated.
Members
Mr. Diver, Michael R.
Research Specialties
Smith, Charles
Accomplishments
Eight years of experience in metal jetting
Designed and fabricated high speed solder, copper, and aluminum jet systems printing capability and direct CAD/CAM interface
Producing solder test coupons for PWB
Designed and fabricated a successful copper jetting system for ball generation
Total research contracts of over $2.5 million and $200,000 of donated equipment and facilities.
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Research Center Profile
817-272-3168 
7300 Jack Newell Blvd. S.Fort Worth, TX 76118
(817) 272-5952 
