GoKawiilResearchers 3D-print ultralong single crystals using pulsed heat control
A research team developed an additive manufacturing method that produces ultralong, architected single crystals by precisely modulating current in a pulsed heat-input process. Using a deep-squat pulsed mode alternating between peak and base currents, they created shallow, wide melt pools with convex solid-liquid interfaces that eliminate unwanted grain formation layer by layer. The team validated their thermal model against experimental and infrared observations, including failure modes like structural collapse from excess heat and unmelted wire from insufficient heat.
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This approach could offer a new route to manufacturing large single-crystal components without the size limitations of traditional crystal-growth techniques, which may matter for industries needing defect-free materials such as aerospace or energy. The precise current control described suggests a pathway to scaling up single-crystal production for architected, complex shapes rather than simple geometries, though practical industrial adoption would depend on further validation beyond the modeled and tested conditions.
- Pulsed current modulation between peak and base values enables controlled melt-pool shapes that eliminate grain boundaries during printing.
- The thermal model's predictions matched experimental melt-pool shapes and infrared data across multiple current conditions.
- Constant current settings that were too high or too low caused structural collapse or unmelted wire, underscoring the importance of precise pulsing.
Source: nature.com — Liu, 2026-10-21
Published there as: “Additive manufacturing of ultralong and architected single crystals”
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