Research
MATERIAL EXTRUSION
DREAMS Lab has advanced multi-axis robotic FFF to overcome anisotropy by enabling non-planar toolpaths, demonstrating property improvements over conventional planar extrusion. In the DIW space, we systematically study the rheology, curing kinetics, and thermal behavior of our inks to ensure processability and shape retention. We link ink flow properties to print fidelity, curing response, and final part performance.
VAT PHOTOPOLYMERIZATION
At the DREAMS Lab, we have advanced VPP beyond conventional photopolymers by demonstrating the first stereolithographic printing of all-aromatic polyimides using photo-curable precursors. This breakthrough enabled access to high-temperature-resistant polymers with applications in aerospace and electronics. Our work highlights the combination of advanced resin chemistry and computational modeling to expand VPP into new material domains.
MULTI-AXIS ROBOTIC DEPOSITION
The research at DREAMS Lab encompasses developing robotic slicing and toolpath strategies that improve interlayer bonding and mechanical performance relative to conventional planar deposition along with conformal printing of conductive traces and Elastomeric materials. In the past, the RAV-FAB project utilised this technology to build a fully functional quadcopter (drone) using autonomous fabrication: combining free-form 3D printing with robotic pick-and-place operations and a set of modular electronics.
DIRECTED ENERGY DEPOSITION
Our research explores multi-scale modeling and experimental evaluation of microstructure in DED. We focus on optimizing deposition parameters to minimize residual stresses and distortion, developing new toolpathing strategies and incorporating scanning for error detection and resolvement. In addition, the lab engages in WAAM adaptation of robotic systems for large-scale Multi-axis builds.
BINDER JETTING
Our studies examined how powder size distribution and bimodal mixtures affect packing density and final sintered properties, providing insight into parameter-material interactions. Other projects include 'shell-printing' approaches to look at varying binder deposition quantities and patterns. These findings help guide the development of higher-density, higher-performance parts in metal Binder Jetting, expanding its applicability in structural applications.
METAL POWDER BED FUSION
We investigate the relationship between processing parameters, thermal history, and microstructural evolution in the metal laser powder bed fusion (LPBF) process. By systematically studying stainless steel 316L, we reveal how part-scale thermal histories govern grain morphology, size distribution, porosity, and defect formation. Our research combines computational thermal history modeling with experimental microstructural analysis, enabling direct correlation between process conditions and resultant material performance.
POLYMER POWDER BED FUSION
We investigate the relationship between processing parameters, thermal history, and microstructural evolution in the metal laser powder bed fusion (LPBF) process. By systematically studying stainless steel 316L, we reveal how part-scale thermal histories govern grain morphology, size distribution, porosity, and defect formation. Our research combines computational thermal history modeling with experimental microstructural analysis, enabling direct correlation between process conditions and resultant material performance.
MATERIAL JETTING
Our research at the DREAMS Lab has characterized mechanical variability and anisotropy in PolyJet materials, showing how build orientation and part aging affect performance. These findings are critical for validating Material Jetting in engineering applications. Beyond characterization, we have applied MJ to biomedical constructs and embedded RF/electronic structures, leveraging its precision and material-mixing capabilities to explore new functional domains. Current projects also involve predicting the jettability of high viscosity materials using modelling techniques.
