Mechnano optimises 3D printing materials with carbon nanotubes – Interview with Dr. Olga Ivanova

Arizona-based company Mechnano is making significant strides in the additive manufacturing industry by advancing material technology, particularly in carbon nanotube (CNT) composites. Co-founded by Scott Gillette and Steven Lowder, the company focuses on applying its proprietary CNT technology to enhance the performance of polymers for the additive manufacturing industry. In an interview with 3Druck.com, Director of Technology Dr. Olga Ivanova shares her expertise in carbon nanotubes and highlights their advantages for enhancing 3D printed parts.

Mechnano has achieved a key breakthrough by successfully integrating carbon nanotubes into parts using material jetting and vat photo-polymerisation systems, allowing for the production of parts with improved impact and tear resistance, enhanced tensile strength, and effective Electrostatic Discharge (ESD) properties. Their proprietary technology, D’Func, plays a crucial role in these advancements by incorporating discrete, dispersed, and functionalised carbon nanotubes into AM materials, significantly improving their mechanical properties.

This innovative approach expands the limits of what AM materials can achieve. D’Func enhances key material properties, providing benefits in a wide range of applications, particularly in industries requiring robust, high-performance materials, such as aerospace, automotive, and electronics.

As the demand for more durable and functional AM materials grows, Mechnano’s continued focus on research and development positions the company as a leader in the integration of nanotechnology with 3D printing, pushing the boundaries of what can be achieved in the field.

Interview with Mechnano’s „Dr. O“

In an interview with 3Druck.com, Olga „Dr. O“ Ivanova, Director of Technology at Mechnano, discusses the importance of advancing materials for additive manufacturing to enhance design flexibility, performance, and efficiency across industries. She highlights the potential of incorporating materials like carbon nanotubes, despite challenges in dispersion and cost, and emphasises that ongoing innovations in material science will continue to drive AM’s growth and impact, from aerospace to healthcare, with a focus on sustainability and customised applications.

In your opinion, what is the significance of developing and improving materials for additive manufacturing processes?

The importance of continually improving materials for AM processes cannot be overstated. AM has transformed the manufacturing industry with its unparalleled design flexibility, cost-efficiency, and rapid prototyping capabilities. Enhancing materials like polymers, metals, and ceramics used in AM, opens up new possibilities for creating intricate geometries, lightweight structures, and customised parts with exceptional mechanical, thermal, or electrical performance.

The development of new materials for AM significantly broadens the technology’s capabilities and potential applications. With the creation of new materials and the optimisation of existing ones, industries can employ AM for a wider range of products. Through research and development in material science, we ensure that AM continues to drive innovation, efficiency, and sustainability in various sectors.

What are the benefits of incorporating carbon nanotubes into 3D printing materials, and what are the challenges that might be encountered in the process?

Incorporating carbon nanotubes into AM materials can yield significant advantages, such as improved performance and the introduction of new properties like conductivity. The addition of carbon nanotubes can enhance the mechanical strength, thermal conductivity, and electrical properties of the fabricated components. This, in turn, creates opportunities for diverse applications across industries ranging from aerospace to electronics.

Nevertheless, this process also comes with several challenges. One major hurdle is the need to effectively detangle and disperse carbon nanotubes throughout the material to maximise their beneficial properties and to ensure their stability. Obtaining uniform and stable dispersion is crucial for achieving consistent results and preventing weak points in the final product. Additionally, the cost of carbon nanotubes remains a challenge, as they are relatively expensive materials. Balancing performance benefits with cost considerations will be a key aspect to address when incorporating carbon nanotubes into AM materials in a practical and economical manner.

Additive manufacturing has continued to develop over the last few years. What innovations or technological breakthroughs do you think are particularly important on the materials side?

In recent years, there have been notable material advancements in the realm of AM, expanding the capabilities and potential applications of the technology. Composite materials have experienced significant growth in the AM sector, with materials reinforced with carbon, glass, and Kevlar fibres as well as carbonaceous nano materials such as carbon nanotubes and graphene gaining popularity. One of my favourites is Sandvik’s diamond composite for 3D printing, showcasing remarkable hardness.

The demand for soft and flexible elastomeric materials in AM has surged, leading to significant growth in the industry. Many companies have launched a variety of soft and flexible materials to cater to the needs of consumer, medical, and industrial sectors. These materials are sought after for their strong and tough properties, making them ideal for applications such as footwear, orthopaedic insoles, and other products. One prominent example is the innovative work being done by Chromatic 3D that demonstrates the impressive advancements in this field.

Furthermore, there has been a recent emphasis on the use of recyclable materials, particularly resins derived from bio sourced materials, to meet the growing demand for environmentally sustainable production practices. 

The variety of materials now accessible for AM has substantially increased. While polymers continue to dominate, there has been a significant growth in the introduction of novel metals, ceramics, and glasses for AM processes. 

What impact do you think additive manufacturing will have on different industries and possibly society as a whole in the coming years?

AM is already establishing a strong presence across various industries and is poised to continue making a significant impact. For instance, personalised prosthetics, implants, and dental products are extensively employed in the healthcare and medical device sectors. Advancements in processing living tissues have the potential to revolutionise transplant medicine. Another example, the aerospace and automotive industries are adopting AM for its capability to fabricate lighter components enhancing fuel efficiency. Implementing AM technology in educational institutions has the potential to enhance STEM education and foster innovation.

AM plays a crucial role in sustainability efforts, particularly as many materials companies are now focusing on producing environmentally friendly feedstocks. The emergence of new job positions geared towards AM, like Design for Additive Manufacturing (DfAM) and materials and processes specialists, highlights the societal impact of this field. 

Although AM technology shows great potential, it is important to recognize that its complete effects may not be seen immediately. Numerous obstacles must be resolved for widespread acceptance in all sectors. I am optimistic that the AM industry will successfully navigate these challenges.

Here you can find more information on Mechnano.