A blue-gloved hand holds a glass plate with a small off-white rectangular prism approximately one quarter the area of a fingernail in cross-section.

AI Helps Researchers Discover New Structural Materials

February 27, 2025 by Navarre Bartz 18 Comments

Nanostructured metamaterials have shown a lot of promise in what they can do in the lab, but often have fatal stress concentration factors that limit their applications. Researchers have now found a strong, lightweight nanostructured carbon. [via BGR]

Using a multi-objective Bayesian optimization (MBO) algorithm trained on finite element analysis (FEA) datasets to identify the best candidate nanostructures, the researchers then brought the theoretical material to life with 2 photon polymerization (2PP) photolithography. The resulting “carbon nanolattices achieve the compressive strength of carbon steels (180–360 MPa) with the density of Styrofoam (125–215 kg m⁻³) which exceeds the specific strengths of equivalent low-density materials by over an order of magnitude.”

While you probably shouldn’t start getting investors for your space elevator startup just yet, lighter materials like this are promising for a lot of applications, most notably more conventional aviation where fuel (or energy) prices are a big constraint on operations. As with any lab results, more work is needed until we see this in the real world, but it is nice to know that superalloys and composites aren’t the end of the road for strong and lightweight materials.

We’ve seen AI help identify battery materials already and this seems to be one avenue where generative AI isn’t just about making embarrassing photos or making us less intelligent.

Software Lets You Paint Surface Patterns On 3D Prints

January 25, 2025 by Adam Fabio 19 Comments

Just when you think you’ve learned all the latest 3D printing tricks, [TenTech] shows up with an update to their Fuzzyficator post-processing script. This time, the GPL v3 licensed program has gained early support for “paint-on” textures.

Fuzzyficator works as a plugin to OrcaSlicer, Bambu Studio, and PrusaSlicer. The process starts with an image that acts as a displacement map. Displacement map pixel colors represent how much each point on the print surface will be moved from its original position. Load the displacement map into Fuzzyficator, and you can paint the pattern on the surface right in the slicer.

This is just a proof of concept though, as [TenTech] is quick to point out. There are still some bugs to be worked out. Since the modifications are made to the G-code file rather than the model, the software has a hard time figuring out if the pattern should be pressed into the print, or lifted above the base surface. Rounded surfaces can cause the pattern to deform to fit the surface.

If you’d like to take the process into your own hands, we’ve previously shown how Blender can be used to add textures to your 3D prints.

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Molybdenene whiskers. (Credit: Sahu et al., 2023)

Introducing Molybdenene As Graphene’s New Dirac Matter Companion

November 12, 2023 by Maya Posch 9 Comments

Amidst all the (well-deserved) hype around graphene, it’s important to remember that its properties are not unique to carbon. More atoms can be coaxed into stable 2-dimensional configuration, with molybdenene previously theoretically possible. This is now demonstrated by Tumesh Kumar Sahu and colleagues in a recent Nature Nanotechnology article, through the manufacturing of a 2D molybdenum-based material which they showed to be indeed molybdenene. Essentially, this is a 2D lattice of molybdenum atoms, a configuration in which it qualifies as Dirac matter, just like graphene. For those of us unfamiliar with Dirac materials, this gentle introduction by Jérôme Cayssol in Comptes Rendus Physique might be of use.

Manufacturing process of molybdenene. (Credit: Sahu et al., 2023)

In order to create molybdenene, the researchers started with molybdenum disulfide (MoS₂), which using a microwave-assisted field underwent electrochemical transformation into whiskers that when examined turned out to consist out of monolayers of Mo. The sulfur atoms were separated using a graphene sheet. As is typical, molybdenene sheets were exfoliated using Scotch tape, in a process reminiscent of the early days of graphene research.

Much like graphene and other Dirac materials, molybdenene has many potential uses as a catalyst, as cantilever in scanning electron microscope (SEM) tips, and more. If the past decades of research into graphene has demonstrated anything, it is that what once seemed more of a novelty, suddenly turned out to have endless potential in fields nobody had considered previously. One of these being as coatings for hard disk platters, for example, which has become feasible due to increasingly more efficient ways to produce graphene in large quantities.

Hackaday Prize 2023: Universal Tensile Testing Machine

August 17, 2023 by Lewin Day 4 Comments

Material testing is important in big industry, where manufacturers must be able to trust the properties of the raw materials they’re using. The rest of us generally take a supplier’s word for it that they’re giving us what we’ve paid for. However, you could always take on material testing yourself with the Universal Tensile Testing Machine from [Xieshi Zhang].

Unlike a six-figure industrial machine, this build is much more affordable, costing on the order of $300 to build. It uses an Arduino to read a tensile strain gauge, and is capable of applying up to a kilonewton of force. To achieve this, it uses a NEMA 17 stepper motor driving a lead screw to apply tensile strain or compression to the specimen under test. The test fixture is assembled from 3D-printed components, and built on top of a piece of aluminium extrusion.

Fundamentally, it’s a smaller version of a machine most engineering undergraduates will see in a materials lab experiment. It could be highly useful for anyone wanting to experiment with 3D printed structures; it would be more than capable of testing various filaments and infill types for their tensile and compression performance. Video after the break.

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Hinges Live Inside 3D Prints

May 1, 2023 by Bryan Cockfield 5 Comments

Since desktop 3D printers have become more common, we’ve seen dramatic shifts in all kinds of areas such as rapid prototyping, antique restoration, mass production of consumer goods, or even household repairs that might not have been possible otherwise. There are a lot of unique manufacturing methods that can be explored in depth with a 3D printer as well, and [Slant 3D] demonstrates how one such method known as the living hinge can be created with this revolutionary new tool.

Living hinges, unlike a metal hinge you might pick up at a hardware store, are integrated into the design of the part and made of the same material. Typically found in plastic containers, they allow for flexibility while keeping parts count and cost low. The major downside is that they create stresses in the materials when used, so their lifespan is finite. But there are a number of ways to extend their life, albeit with a few trade-offs.

The first note is to make sure that you’re using the right kind of plastic, but after that’s taken care of [Slant 3D] builds a few flexible parts starting with longer circular-shaped living hinge which allows greater range of motion and distributes the forces across a wider area, at a cost of greater used space and increased complexity. A few other types of living hinges are shown to use less space in some areas, but make the hinges only suitable for use in other narrower applications.

One of the more interesting living hinges he demonstrates is one that’s more commonly seen in woodworking, known there as a kerf bend. By removing strips of material from a sheet, the entire sheet can be rotated around the cuts. In woodworking this is often done by subtracting material with a CNC machine or a laser cutter, but in 3D printing the voids can simply be designed into the part.

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Glass: Classic, But Mysterious

June 11, 2022 by Al Williams 19 Comments

For a large part of human history, people made things from what they could find. Some stones make arrowheads. Others make sparks. Trees can turn into lumber. But the real power is when you can take those same materials and make them into something with very different properties. For example, plant fibers turning into cloth, or rocks giving up the metals inside. One of the oldest engineered materials is glass. You’d think as old as glass is (dating back at least 4,500 years), we’d understand all there is to know about it by now. According to an interesting post by [Jon Cartwright] writing in Physics World, we don’t. Not by a long shot.

According to [Jon] there are at least five “glassy mysteries” that we still don’t understand. Sure, it is easy to just melt sand, soda, and lime — something we’ve talked about before — but, in fact, many materials can turn glassy when cooled quickly from liquid to solid. The problem is, we don’t really understand why that happens. Continue reading “Glass: Classic, But Mysterious” →

Stresses Revealed With A Polariscope

April 1, 2022 by Bryan Cockfield 13 Comments

There are a lot of ways that stresses can show up, at least when discussing materials science. Cracks in concrete are a common enough example, but any catastrophic failure in a material is often attributable to some stress that couldn’t be withstood. If you’re interested in viewing those stresses before they result in damage to the underlying material, take a look at this DIY polariscope which can view internal stresses in glass and other clear objects.

The polariscope takes its name from the fact that it uses polarized light to view the internal structure of a transparent object such as glass. When the polarized light passes through glass in a certain way, the stresses show up as lighter areas thanks to the stressed glass bending the light back into view. This one is constructed with a polarizing filter placed in front of an LCD screen set to display a completely white image. When glass is placed between the screen and the filter no light is seen through the polariscope unless there are stresses in the glass. Even placing a force on an otherwise un-stressed glass tube can show this effect, and [Advanced Tinkering], this project’s creator, has several other creations which show this effect in striking detail.

The effect can also be observed as colored areas in other plastic materials as well. It’s an interesting tool which can help anyone who frequently works with glass, but it’s also interesting on its own to see clues left behind from the manufacturing process of various household items. We’ve seen some other investigative methods for determining how other household items are mass produced as well, like this project which breaks down the injection molding process.

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