Researcher(s)
- Colby Dolbow, Computer Engineering, University of Delaware
Faculty Mentor(s)
- Nathan Lazarus, Computer and Electrical Engineering, University of Delaware
Abstract
Introduction
There is a need for quick access to replacement electrical components to ensure operations (military, hospital, etc.) can proceed without excessive delays that often occur with standard manufacturing and shipping methods. Using a 3D printer is one way to produce temporary electrical replacement parts quickly and inexpensively until the more refined components are received.
Materials & Methods
SolidWorks was used to create a 3D toroidal inductor design that was put into the FDM 3D printer’s slicer software to produce the print file. Standard PLA plastics were used for structure, and conductive Protopasta composites were used for its electrical conductivity. After printing, the conductive PLA composite was electroless plated, covering only the conductive composite in a thin layer of copper all the way around to increase electrical conductivity of the inductor.
Result
Traditional circular and square toroidal inductor prototypes were attempted with the square designs yielding more consistent results. Seven square prototypes were attempted and failed due to printer inconsistencies such as extruder misalignment, incorrect temperatures, and excess filament. Multiple researchers using the same printer complicated troubleshooting printer configuration issues. Two inductors were successfully printed and electroless plated producing a conductive prototype. These copper electroless plated inductors had a resistance of approximately 500 ohms around the coil and were too resistive to test. However, they had approximately 200 times less resistance than the non-plated Protopasta composite which had a resistance of approximately 100,000 ohms. The resistance ratio between the copper electroless plated inductor and the non-plated inductor was 1:200.
Discussion
Further research must be conducted to find ways to increase the effectiveness of the plating process. Additionally, the full electroplating process needs to be tested for effectiveness compared to the electroless plating process. The electroplating process is significantly more involved than electroless plating but should yield more consistent results. By obtaining a better understanding of the benefits and limitations of the plating options, further progress can be made in achieving the goal of using 3D printers to produce temporary electrical replacement parts quickly and inexpensively so that operations (military, hospital, etc.) can proceed without long delays. This is of critical importance as the temporary replacement parts can be a determining factor in the success or failure of the operations.