Robocasting

The technique was first developed in the United States in 1996 as a method to allow geometrically complex ceramic green bodies to be produced by additive manufacturing.

Numerically controlled mechanisms are typically used to move the nozzle in a calculated tool-path generated by a computer-aided manufacturing (CAM) software package.

For example, the inclusion of stiff boron nitride nanobarbs within epoxy feedstock has been demonstrated to anisotropically increase overall composite strength and stiffness along the direction of fiber orientation due to their shape asymmetry,[9] while the inclusion of hollow glass microspheres within the same epoxy feedstock has been demonstrated to isotropically improve specific strength by significantly reducing total density of the composite.

In addition, very long fibers have exhibited a tendency to break during extrusion, essentially imparting a de facto size cap on filament-type fillers used in robocasting.

The creation of open lattice-type structures via robocasting is widespread and enables optimization of specific strength and stiffness by reducing the cross-sectional footprint of a given feedstock material while retaining much of its bulk mechanical integrity.

[13][14][15] In addition, the creation of unique deposition pathing via finite element analysis of a desired structure can generate dynamically-graded geometries optimized for specific applications.

A wide variety of different geometries can be formed from the technique, from solid monolithic parts[2] to intricate microscale "scaffolds",[17] and tailored composite materials.

"Woodpile" stacked lattice structures can be formed quite easily which allow bone and other tissues in the human body to grow and eventually replace the transplant.

[19] Other potential applications include the production of specific high surface area structures, such as catalyst beds or fuel cell electrolytes.