Finite Element Simulation of Microwave Technologies for PowderBased Volumetric Additive Manufacturing Processes

Abstract

Volumetric additive manufacturing (VAM) is a promising field of advanced manufacturing which reduces production times of conventional 3D printing while retaining application to complex geometries. Current VAM systems are limited to photo-polymerizing resins, which reduces the general applicability across industry. This work presents exploratory finite element simulations of microwave-based VAM systems compatible with ceramic, metal, or composite powder feedstock. The simulations explore three devices -- a linear resonator, a cross interferometer, and a boundary heater -- each with potential uses in manufacturing processes for one or multiple of the considered feedstock materials. We find that with precise control of input frequency, power, and waveguide transverse modes, thermal lattices can be engineered to selectively heat regions of the feedstock, allowing direct application to VAM. Resultant lattices have cellular dimensions on the order of 1 mm, and require input powers on the order of 100 kW. With advances in microwave technologies allowing for this precision, such devices could open pathways to VAM with materials currently outside the scope of optical methods.