Grant: Discovery Grants Program - Individual

Additive manufacturing (AM), also called 3D-printing, is slated to change the entire manufacturing enterprise by 2030. Despite the hype, AM has not yet prevailed in industry due to major drawbacks, especially in metals, such as high costs per part and limited materials selection. Metal fused filament fabrication (FFF) is the most accessible, material-efficient, and affordable (costing <$1k) type of metal AM technology which has been recently tapped by a range of aerospace and automotive industries for 3D-printing fully metal functional parts. However, metal FFF is a young niche and the available knowledge for developing fully metal parts by FFF from a wide range of materials selection is still very limited. It is also important to note that the future is more than metals and there is a multi-decade trend underway to transition parts from metals to advanced composites, which are lighter and offer greater efficiencies. With the integration of nanotechnology and AM, unique possibilities for developing 3D-printing nanocomposite materials have come into scope. However, there exists a significant knowledge gap on integrating a variety of nanomaterials into low-cost AM to fabricate high performance and multifunctional hybrid nanocomposite components for next generation functional devices. In addition, sustainable development of metals and composites are indispensable in the context of circular economy and manufacturing which strongly focus on reuse, repair, remanufacturing and recycling; so, it is critical to develop new feedstock materials for fabrication of functional filaments for low-cost FFF to democratize use of innovative recyclable filaments and enable multifunctional part 3D-printing using low-cost and lower-energy consumption equipment. As such the long-term objective of my research program is to develop innovative materials and methodologies to create sustainable recyclable products for low-cost point-of-need manufacturing of metals and composites, helping to strengthen AM supply chains and foster AM adoption by the manufacturing masses. The short-term objectives include: 1) study and develop recyclable novel metal-infused polymeric filaments for low cost FFF fabrication of fully metal parts, and 2) investigate and develop recyclable novel nanocomposite filaments for low cost FFF fabrication of multi-filler hybrid nanocomposite with multifunctional properties. This research program has a significant value to contribute to the recent Canadian Government sustainability goals-"2030 Agenda and the Sustainable Development Goals"- to generate a circular economy model for Canadian industry and even beyond. To prevent depletion of Canada's rich natural resources (e.g. metals), the proposed research will use the environmentally-extracted recycled metal powders to develop novel metallic filled feedstock for FFF. This research will also provide substantial HQP training opportunities and have a lasting impact on the Canadian economy.