eprintid: 10204291 rev_number: 9 eprint_status: archive userid: 699 dir: disk0/10/20/42/91 datestamp: 2025-02-04 11:09:11 lastmod: 2025-02-04 11:09:11 status_changed: 2025-02-04 11:09:11 type: article metadata_visibility: show sword_depositor: 699 creators_name: Hagger, Oliver SJ creators_name: Parkes, Michael A creators_name: Estrin, Francis Lockwood creators_name: Agrotis, Stefanos creators_name: Parkin, Ivan P creators_name: Handoko, Albertus D creators_name: Caruana, Daren J title: Additive metal printing on multi materials using an atmospheric pressure plasma jet on a 5-Axis platform ispublished: inpress divisions: UCL divisions: B04 divisions: C06 divisions: F56 note: This work is licensed under a Creative Commons License. The images or other third-party material in this article are included in the Creative Commons license, unless indicated otherwise in the credit line; if the material is not included under the Creative Commons license, users will need to obtain permission from the license holder to reproduce the material. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/ abstract: Post-production embellishment of objects with metal tracks presents challenges, due to the need for multiple processing steps and the complexity of navigating intricate substrate geometries. Here we describe a flexible approach to deposit conducting metal tracks on 3D objects using an atmospheric pressure plasma jet (APPJ). APPJs offer distinct advantages over traditional inkjet printing methods as they do not require metal particle inks or post-processing. An in-house-built APPJ print head was mounted onto a 5-axis platform to demonstrate metal printing on multifaceted metal, ceramic and glass complex objects. We use finite element modelling of the flow characteristics at the jet nozzle exit to understand and predict the track deposition. The modelling was corroborated through Schlieren imaging of the gas flow as well as chemical and physical characterisation of the resulting deposited track. Conductive metallic tracks of 0.3 mm widths were deposited on non-planar surfaces with one pass at a rate of 1 mm/s, using simple aqueous metal salts with an average plasma power of 10 W. Our findings reveal conductivity, adhesion strength and precision which present a benefit for additive manufacturing. date: 2025-01-31 date_type: published publisher: Elsevier BV official_url: https://doi.org/10.1016/j.matdes.2025.113681 oa_status: green full_text_type: other language: eng primo: open primo_central: open_green verified: verified_manual elements_id: 2357848 doi: 10.1016/j.matdes.2025.113681 lyricists_name: Caruana, Daren lyricists_name: Parkes, Michael lyricists_name: Hagger, Oliver lyricists_id: DJCAR76 lyricists_id: MPARK22 lyricists_id: OHAGG64 actors_name: Caruana, Daren actors_id: DJCAR76 actors_role: owner full_text_status: public publication: Materials & Design article_number: 113681 citation: Hagger, Oliver SJ; Parkes, Michael A; Estrin, Francis Lockwood; Agrotis, Stefanos; Parkin, Ivan P; Handoko, Albertus D; Caruana, Daren J; (2025) Additive metal printing on multi materials using an atmospheric pressure plasma jet on a 5-Axis platform. Materials & Design , Article 113681. 10.1016/j.matdes.2025.113681 <https://doi.org/10.1016/j.matdes.2025.113681>. (In press). Green open access document_url: https://discovery.ucl.ac.uk/id/eprint/10204291/1/Caruana_1-s2.0-S0264127525001017-main.pdf