In a breakthrough that could revolutionize the electronics and energy sectors, researchers have unlocked the potential of molten metal jetting (MMJ) to print high-resolution, pure silver structures with tailored microstructures. This advancement, published in the journal *Materials Today Advances* (translated as “Advances in Materials Today”), could pave the way for more efficient and precise manufacturing processes, particularly in high-temperature applications.
Led by Negar Gilani at the Centre for Additive Manufacturing at the University of Nottingham in the UK, the research team developed a comprehensive framework to understand and control the MMJ process for pure silver. “We focused on droplet dynamics, solidification kinetics, and interfacial bonding mechanisms,” Gilani explained. “By precisely controlling the droplet and substrate temperatures, we were able to print fully consolidated pure silver structures without the need for post-manufacturing heat treatments.”
The study revealed that thermal conditions play a crucial role in the formation of various microstructures. Rapid cooling rates of 16–23°C per micrometer per second promoted the development of fine equiaxed grains at the interface, followed by directional columnar grains, with annealing twin grain boundaries forming under these conditions. In contrast, slower cooling rates, such as 3.5°C per micrometer per second, due to increased substrate temperatures, resulted in larger grains and the formation of single-crystal structures within the droplets.
“This level of control over microstructure is a game-changer,” said Gilani. “It opens new possibilities for tailored microstructure control through MMJ, which could enable the fabrication of high-resolution electronics in silver, driven by the precise printing capabilities of the MMJ process.”
The implications for the energy sector are significant. High-resolution silver structures could enhance the performance of electronic components in renewable energy systems, such as solar panels and wind turbines, by improving conductivity and reducing energy loss. Additionally, the ability to print complex geometries with precise control over microstructure could lead to more efficient and durable components for energy storage and transmission.
As the demand for sustainable and efficient energy solutions grows, the ability to manufacture high-performance electronic components with precision and control becomes increasingly important. This research not only advances the field of additive manufacturing but also brings us closer to realizing the full potential of MMJ in creating high-resolution, tailored structures for a wide range of applications.
The study, published in *Materials Today Advances*, represents a significant step forward in the understanding and application of MMJ technology. As researchers continue to explore the possibilities of this innovative manufacturing process, the potential for transformative impacts on the electronics and energy sectors becomes ever more apparent.