A method of fabricating a three-dimensional (3D) object includes atomizing a pre-polymer composition into an aerosol jet stream. The pre-polymer composition includes an epoxy precursor and a photoacid generator. The method further includes depositing the aerosol jet stream onto a substrate to form a first layer of dielectric ink and curing the first layer of dielectric ink using ultraviolet (UV) light. The method further includes depositing the aerosol jet stream onto the first layer of dielectric ink to form a second layer of dielectric ink. The first layer of dielectric ink and the second layer of dielectric ink overlap by at least 50%.

A method of fabricating a three-dimensional (3D) object includes atomizing a pre-polymer composition into an aerosol jet stream. The pre-polymer composition includes an epoxy precursor and a photoacid generator. The method further includes depositing the aerosol jet stream onto a substrate to form a first layer of dielectric ink and curing the first layer of dielectric ink using ultraviolet (UV) light. The method further includes depositing the aerosol jet stream onto the first layer of dielectric ink to form a second layer of dielectric ink. The first layer of dielectric ink and the second layer of dielectric ink overlap by at least 50%.

Porous and microporous parts prepared by additive manufacturing as disclosed herein are useful in medical and non-medical applications. The parts are prepared from a composition containing both a solvent soluble component and a solvent insoluble component. After a part is printed by an additive manufacturing process it is exposed to solvent to extract solvent soluble component away from the printed part, resulting in a part having surface cavities.

Porous and microporous parts prepared by additive manufacturing as disclosed herein are useful in medical and non-medical applications. The parts are prepared from a composition containing both a solvent soluble component and a solvent insoluble component. After a part is printed by an additive manufacturing process it is exposed to solvent to extract solvent soluble component away from the printed part, resulting in a part having surface cavities.

An example method for forming a strengthened additive manufacturing material includes coating a surface of an additive manufacturing material with a solution including reinforcement particles, and causing a solvent of the solution to evaporate and the reinforcement particles adhere to the surface of the additive manufacturing material. An example strengthened filament includes a polymer filament having a surface, and reinforcement particles included on the surface of the polymer filament in a substantially uniform coating.

An example method for forming a strengthened additive manufacturing material includes coating a surface of an additive manufacturing material with a solution including reinforcement particles, and causing a solvent of the solution to evaporate and the reinforcement particles adhere to the surface of the additive manufacturing material. An example strengthened filament includes a polymer filament having a surface, and reinforcement particles included on the surface of the polymer filament in a substantially uniform coating.

A composite material includes a plurality of metallic particles formed through modulation-assisted machining. The composite includes a thermoplastic polymer matrix which binds the plurality of metallic particles.

Methods for fabricating a multi-material composite structure are described. Methods for fabricating a multi-material composite structure include forming a first colloidal ink solution with a first material matrix, water, and a rheology modifying agent; forming a second colloidal ink solution with a second material matrix, water, and a rheology modifying agent; printing a first layer on a substrate using a first printing nozzle carrying the first colloidal ink solution; printing a second layer on top of the first layer using a second printing nozzle carrying the second colloidal ink solution; forming a 3D structure by printing a plurality of layers including the first layer and the second layer printed in an alternating pattern; and sintering the 3D structure to form the multi-material composite structure.

Methods for fabricating a multi-material composite structure are described. Methods for fabricating a multi-material composite structure include forming a first colloidal ink solution with a first material matrix, water, and a rheology modifying agent; forming a second colloidal ink solution with a second material matrix, water, and a rheology modifying agent; printing a first layer on a substrate using a first printing nozzle carrying the first colloidal ink solution; printing a second layer on top of the first layer using a second printing nozzle carrying the second colloidal ink solution; forming a 3D structure by printing a plurality of layers including the first layer and the second layer printed in an alternating pattern; and sintering the 3D structure to form the multi-material composite structure.

A method of preparation of a ceramic slurry for use in 3D printing includes steps of: (A) providing a plasticizer and a disperser and mixing the plasticizer and the disperser evenly; (B) mixing the mixture obtained in step (A) with an adhesive, wherein the adhesive is polyvinyl alcohol; and (C) adding a Yttria-stabilized zirconia powder to the mixture obtained in step (B) to produce, by sufficient blending and deaerating, the ceramic slurry for use in 3D printing. A method of preparation of a ceramic product includes steps of: (A) preparing a ceramic slurry with the method; (B) performing 3D printing with the ceramic slurry to form a primary green body; (C) placing the primary green body in a freezer to undergo a refrigeration process, thereby causing crystallization of polyvinyl alcohol; and (D) thawing the frozen primary green body to form a plastic green body with gel structure.