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.