Magnetic components such as inductors and transformers are generally the largest circuit elements in switch-mode power systems for controlling and processing electrical energy. To meet the demands of higher conversion efficiency and power density, there is a growing need to simplify the process of fabricating magnetics for better integration with other power electronics components. The potential benefits of additive manufacturing (AM), or more commonly known as three-dimensional (3D) printing technologies, include shorter lead times, mass customization, reduced parts count, more complex shapes, less material waste, and lower life-cycle energy usage—all of which are needed for manufacturing power magnetics. In this work, an AM technology for fabricating and integrating magnetic components, including the design of manufacturing methodology and the development of the feedstock material, was investigated. A process flow chart of additive manufacturing functional multi-material parts was developed and applied for the fabrication of magnetic components. One of the barriers preventing the application of 3D-printing in power magnetics manufacturing is the lack of compatible and efficient magnetic materials for the printer's feedstock. In this work, several magnetic-filled-benzocyclobutene (BCB) pastes curable below 250 degree C were formulated for a commercial multi-material extrusion-based 3D-printer to form the core part. Two magnetic fillers were used: round-shaped particles of permalloy, and flake-shaped particles of Metglas 2750M. To guide the formulation, 3D finite-element models of the composite, consisting of periodic unit cells of magnetic particles and flakes in the polymer-matrix, was constructed. Ansoft Maxwell was used to simulate magnetic properties of the composite. Based on the simulation results, the pastes consisted of 10 wt% of BCB and 90 wt% of magnetic fillers—the latter containing varying amounts of Metglas from 0 to 12.5 wt%. All the pastes displayed shear thinning behavior and were shown to be compatible with the AM platform. However, the viscoelastic behavior of the pastes did not exhibit solid-like behavior, instead requiring layer-by-layer drying to form a thick structure during printing. The key properties of the cured magnetic pastes were characterized. For example, bulk DC electrical resistivity approached 107 Ω⋅cm, and the relative permeability increased with Metglas addition, reaching a value of 26 at 12.5 wt%. However, the core loss data at 1 MHz and 5 MHz showed that the addition of Metglas flakes also increased core loss density. To demonstrate the feasibility of fabricating magnetic components via 3D-printing, several inductors of differing structural complexities (planar, toroid, and constant-flux inductors) were designed. An AM process for fabricating magnetic components by using as-prepared magnetic paste and a commercial nanosilver paste was developed and optimized. The properties of as-fabricated magnetic components, including inductance and DC winding resistance, were characterized to prove the feasibility of fabricating magnetic components via 3D-printing. The microstructures of the 3D-printed magnetic components were characterized by Scanning-electron-microscope (SEM). Results indicate that both the winding and core magnetic properties could be improved by adjusting the formulation and flow characteristics of the feed paste, by fine-tuning printer parameters (e.g., motor speed, extrusion rate, and nozzle size), and by updating the curing profile in the post-process. The main contributions of this study are listed below: 1. Developed a process flow chart for additive manufacturing of functional multi-material components. This methodology can be used as a general reference in any other research area targeting the utilization of AM technology. 2. Designed, formulated and characterized low-temperature curable magnetic pastes. The pastes are physically compatible with the additive manufacturing platform and have applications in the area of power electronics integration. 3. Provided an enhanced understanding of the core-loss mechanisms of soft magnetic materials and soft magnetic composites at high frequency applications. / Ph. D.

Many manufacturing processes require complex tooling which contributes significantly to the cost and time required to develop new products. Bead foam molding is often hampered by these limitations. This thesis presents an analysis of Additive Manufacturing (AM) applications in low cost bead foam molding, focusing on molding trials, economic analysis, and future potential. Through molding trials, the thesis evaluates the efficacy of AM tooling in comparison to traditional aluminum tooling, specifically in evaluating tool life and cost. A key finding is a reduction in lead time up to 70% and cost of up to 63% compared to traditional tooling, particularly in low-volume production scenarios. This thesis includes a detailed cost analysis, which breaks down the cost components associated with AM processes such as pre-processing, production, material costs, post-processing, and overheads. This analysis reveals that AM tooling can offer substantial cost savings over conventional methods, making it a viable option for specific manufacturing contexts. Findings suggest that while AM tooling shows significant promise in reducing costs and accelerating production in bead foam molding, further research is required. This research should focus on exploring the scalability of AM for larger tools and investigating the application of new and emerging AM processes and materials. / Master of Science / This thesis explores the use of Additive Manufacturing (AM), often known as 3D printing, in creating molds for bead foam molding—a process used in manufacturing a variety of foam products. Findings reveal that using AM for toolmaking can be faster and more cost-effective than traditional methods, especially for small-scale production. The thesis details experiments comparing AM with conventional tooling and presents a cost analysis showing the potential time and cost savings. While promising, further research is needed to fully harness the benefits of AM in this field. This study opens doors to more efficient and economical manufacturing techniques using emerging AM technology.

<p> </p> <p>Alloys manufactured using additive manufacturing (AM) techniques have been increasingly used for medical and structural applications. However, their corrosion properties are not sufficiently studied which hinders their use in applications, such as orthopedic implants and ocean structures. The objective of this thesis is to systematically investigate the corrosion and mechanical properties of polymer-coated additively manufactured (AM’ed) 316L stainless steel (SS) and Ti-6Al-4V(Ti64) titanium alloys, thus understanding their structure-property relationships, which will provide the guidelines for the use of these alloys in corrosive environments.</p> <p>To achieve the objective, the following research tasks have been identified: (1) characterization of the corrosion properties of AM’ed and conventional wrought 316L SS; (2) study of the mechanical and corrosion properties of epoxy coated AM’ed and conventional wrought 316L SS; (3) investigation of biocompatible polymer coated 316L SS and Ti64 alloy; (4) machine learning-based lattice structure design of AM’ed alloys; and (5) development of computational models to simulate the mechanical and corrosion properties of the AM’ed alloys.</p> <p>The results show that the corrosion potential of AM’ed 316L SS is lower, but the corrosion rate is higher than that of conventional 316L SS. From the phase-field model of corrosion, the corrosion area increases with the corrosion time, the number of holes, and the size of holes.</p> <p>The epoxy-coated 316L SS shows a bond strength of 1.68 MPa and 1.81MPa for the conventional and AM’ed 316L SS, respectively. The molecular dynamics (MD) model illustrates that the interface bond is broken in the epoxy layers, and the mechanical strength increases with strain rate and decreases with temperature. The electrochemical tests show that the coating layer improves the anti-corrosion properties compared to the uncoated specimens. The Monte Carlo (MC) model illustrates that the polymer has good adhesion properties on the substrate with anti-corrosion behavior, indicated by low adsorption energy in NaCl solution.</p> <p>For the AM’ed 316L SS and Ti64, Young’s modulus and yield strength are similar to the conventional counterparts. The Tafel polarization results show that both uncoated AM’ed 316LSS and Ti64 have higher corrosion potential and current density than the uncoated conventional ones. The biocompatible polymer coated AM’ed 316L and Ti64 samples demonstrate relatively low cytotoxicity.</p> <p>The developed neural network (NN) model is capable to predict reasonably well about Young’s modulus and yield strength of AM’ed alloys. An example of lattice structure is designed with matching mechanical properties with natural bones.</p>

This study focuses on the cycle-averaged mold temperature of additively manufactured injection molding tooling and how it is affected by conformal cooling channels. This was done by producing a benchmark mold out of Digital ABS produced by Stratasys, an acrylic based photopolymer, which was then used to produce injection molded parts until tool failure. Another, more cost-effective material, High Temp Resin produced by Formlabs, another acrylic based photopolymer, was also tested but yielded very little success. Then the mold design was altered by adding conformal cooling channels and again tested by producing injection molded parts while tracking the mold temperature. This experimentation was then compared to an injection molding cooling channel model in order to validate the model for use with additively manufactured tooling with conformal cooling channels for use in injection molding. The benchmark Digital ABS mold was able to produce 66 shots in the injection molding machine before complete mold failure. The Digital ABS mold had a cycle-averaged mold temperature of about 155°F. The High Temp Resin mold was able to produce 3 shots before complete mold failure. The High Temp Resin material is much more brittle, and the mold design did not take into account how brittle the material was. The Digital ABS mold with conformal cooling channels had a cycle-averaged mold temperature of 111°F. This is significantly lower than without cooling channels and has a high potential for improving tooling life. The cooling channel model predicted the cycle-averaged mold temperature to be 116°F. This proved to be a very good model and can be used as a design tool when choosing cooling channel geometry and position in additively manufactured tooling. This research shows the potential that conformal cooling channels have to help improve additively manufactured tooling life for injection molding. As shown in other research done, the ability to maintain the mold below 120°F significantly improves the life of additively manufactured tooling. The results of this study demonstrate the effectiveness of conformal cooling channels in controlling mold temperature. It should be researched further, but the use of conformal cooling channels has the potential to produce more production or prototype parts with additively manufactured tooling for injection molding.

No description available.

Self-oscillating synthetic vocal fold (VF) models are often used to study human voice production. In this thesis, a method for fabricating multi-layer self-oscillating synthetic VF models using silicone 3D printing is presented. Multi-material 3D printing enables faster fabrication times with more complex geometries than traditional casting methods and builds a foundation for producing VF models with potentially more life-like geometries, materials, and vibratory characteristics. The printing method in this study used a custom dual extruder and slicing software to print UV-curable liquid silicone into a gel-like support matrix. The extruder was fabricated using high-torque stepper motors with high resolution leadscrews for precise extrusion and retraction. The custom slicing software accounted for challenges with printing a low-viscosity uncured silicone and was capable of allowing the user to visually observe the effects of print settings on print paths before finalizing the g-code. Three validation tests were conducted to demonstrate the 3D printer’s ability to print ultra-soft silicone with the desired range of stiffness, change between materials quickly, and print a material stiffness gradient. Two types of VF models were printed in this study, a previously-designed model with multiple distinct layers (“EPI” model), and the same model but with a vertical stiffness gradient (VSG) in the superficial lamina propria layer. The EPI model was chosen to demonstrate the ability to 3D print a multi-layer model, and the VSG model was chosen to demonstrate the ability to print multi-material VFs with geometric and material properties that are difficult to fabricate using traditional casting methods. Sixteen VFs (i.e., eight pairs) of each model type were printed, and their vibratory responses were recorded, including onset pressure, frequency, and glottal width. A micro-CT scanner was used to evaluate the external geometric accuracy of the models. One-centimeter cubes were 3D printed and tensile tested to characterize the material properties of each set of VF models. The material and phonatory properties of both the EPI and VSG VF models were found to be comparable to human data and to previous data acquired using synthetic VF models fabricated via other methods. In this thesis, the 3D printing methodology is summarized, the setup and results of the validation and VF model tests are reported and discussed, and recommendations for future work are provided.

<p>  </p> <p>Laser powder bed fusion (L-PBF) is a relatively young metallurgical processing method which has many advantages over traditional casting and wrought based methods. Alloy systems suitable for this additive manufacturing (AM) process include Ti-6Al-4V, 316 stainless steel, Inconel 718 and 625 making it attractive for automotive, aerospace, and biomedical applications. Despite the potential, L-PBF is plagued by defects and inconsistent build qualities which make certification of critical components onerous. Additionally, experimental studies are difficult due to the cost of laser systems and feedstock material. Many researchers have turned to computational modeling as this allows for rigorous examination and isolation of the underlying physics to better understand where problems may arise, and where improvements can be made. However, models often fail to consider the role of systematic and statistical uncertainty while also relying heavily on assumptions and simplifications for computational efficiency. As such, there is no quantifiable metric for how reliable these models are. This work applies an uncertainty quantification (UQ) framework to computational models for L-PBF to understand the role of uncertainty and assumptions on model reliability as this provides insight into their limitations and potential areas of improvement.</p> <p>First, the UQ framework is applied to a finite volume melt pool transport model to evaluate the role of uncertainty and model assumptions on melt pool shapes and solidification dynamics. This includes the role of simulating the powder bed thermophysical properties, surface tension driven Marangoni convection, and the thermodynamic relation dictating latent heat release. The transport model is then weakly coupled to a cellular automata (CA) grain evolution model to propagate and quantify the uncertainty in the as-built microstructure including crystallographic texture formation. Further propagation of melt pool and microstructure uncertainty to the resulting mechanical properties to close the process-microstructure-property relations are discussed. Lastly, recommendations for future model development and research are presented. </p>

There is a gap in scientific knowledge regarding designing functional parts that may not fail, and this project came to define these parts as critical structures. The proposed design process is called the Additive Design Process for Critical Structure, which synthesizes required activities found in the literature review necessary to produce theoretically safe design structures. Although this proposed design process does not meet the requirements of a safe design as intended and must be further studied before the proposed design process can be adapted. The project’s ambition was to integrate the design’s safety with value components, referred to as elements/activities/tools/processes that could contribute to innovation and value creation, to exploit the advantages of additive manufacturing in the design process. The research conducted in this project adapted and applied Design Research Methodology (DRM), written by Blessing &amp; Chakrabarti (2009). Two main research questions were studied that lay a foundation for this thesis, presented below. The project combined quantitative and qualitative research methods to generate the necessary knowledge and then apply/test the derived knowledge to answer these research questions. RQ1: What activities can this project identify to synthesize an additive design process in constructing critical structures for Additive Manufacturing (AM)? RQ2: What are the possible value components to include in the additive design process that would contribute to innovation concerning lead time, weight, and mass customization? The results show that the proposed design process, Additive Design Process for Critical Structured, did not meet the theoretical safe design. However, the findings still suggest that the required activities to achieve a safe design are by introducing defined and explicit protective measurements in the design process. The protective measurement parameters identified in this project were safety factors and Finite Element Analysis (FEA); the question of why the design process does not meet the requirements of producing a theoretical safe design is unknown today and needs further study. Concerning the second RQ, the results showed that Generative Design (GD) was this project's most innovative value component. Adapting GD contributed to shortening the product development time, liberating the design engineer to explore a bolder concept, reducing weight, and allowing the design engineers to generate mass customization. Keywords: Design for Additive Manufacturing, Design Process, Generative Design, Method, Critical Structures, Safety factor.

Ultrafast lasers are valuable research and manufacturing tools. The ultrashort pulse duration is comparable to electron-lattice relaxation times, yielding unique interactions with matter, particularly nonlinear absorption, melting, and ablation. The field of ultrafast laser manufacturing is rapidly evolving with advances in related laser technologies. The applications of ultrashort pulse lasers in additive manufacturing aim to fill gaps left by conventional techniques especially on the nano- and micro-scale. Concurrently, uptake of ultrafast fiber lasers for micromachining has increased, and may replace the Ti:Sapphire laser as the ultrafast laser of choice. Both additive and subtractive manufacturing are accomplished with ultrafast lasers which presents the possibility of hybrid, all-in-one devices using a single laser source. As one such combination of laser techniques, ultrashort pulse surface modification of additively manufactured metals is an area of limited investigation. This thesis aims to address the ever-changing landscape of ultrafast laser manufacturing by 1) reviewing ultrafast laser additive manufacturing techniques and recent advancements 2) comparing the design, operation, and micromachining potential of a commercial ultrafast Ti:Sapphire and ultrafast fiber laser, and 3) investigating femtosecond ablation of as-printed additively manufactured Ti-6Al-4V at a range of parameters to test the feasibility of surface feature control. Ultrafast laser additive manufacturing is still in its infancy with mostly niche applications. The ultrafast fiber laser architecture is found to deliver a platform that is easier to operate and maintain and has superior micromachining throughput relative to Ti:Sapphire lasers. In our experimental work, five main surface morphologies are obtained by femtosecond ablation of a rough Ti-6Al-4V surface: laser-induced periodic surface structures (LIPSS), undulating grooves, micro-ripples, grooves, and micro-cavities. Transitions between ablation regimes and evolutions of the surface under increasing pulse energy and number of pulses are observed. These patterns allow for control over the surface geometry without the need for post-printing polishing. / Thesis / Master of Applied Science (MASc) / Ultrafast pulsed lasers of <10 picoseconds pulse duration are commonly used to modify, melt, or ablate materials. As an important research and manufacturing tool, ultrafast lasers and techniques have seen great change in the past two decades. Additive manufacturing has emerged as an area in which ultrafast lasers are becoming increasingly prevalent. To make sense of this continuously evolving landscape, this thesis 1) reviews ultrafast laser additive manufacturing techniques, applications, and advances towards industrial use and commercialisation, 2) compares the setup, operability, and characteristics for two ultrafast laser designs, and 3) investigates the surfaces produced by ultrafast laser irradiation of an additively manufactured titanium alloy part. The surface morphologies that are produced are categorised into five main patterns: laser-induced periodic surface structures, undulating grooves, micro-ripples, grooves, and micro-cavities. Each is a distinct pattern that may allow for tuning of the surface properties with respect to the wettability and biocompatibility.

Additive manufacturing (AM) is a form of production that directly processes raw materials into their final form by building the product in a layer-by-layer fashion. Numerous types of AM exist, including selective laser sintering (SLS) of polymeric powders, vat polymerization (VP) of low viscosity photocurable resins, and material extrusion (MatEx) of thermoplastic or high viscosity composite materials. Because of its ability to reduce material waste while printing complex geometries, AM has the potential to revolutionize the manufacturing industry for a diverse set of materials and products. MatEx of thermoplastic feedstocks is most commonly performed using fused filament fabrication (FFF) – a form of melt extrusion. A solid filament is fed directly into a heated nozzle, where it melts onto a build bed before resolidifying in a matter of seconds. While this is the most common form of AM, especially among hobbyists, the material catalog is limited to thermoplastic polymers, and difficulties arise when fillers are introduced (e.g. reactions at elevated temperatures, clogging, disruption of polymer chain diffusion, and large increases in viscoelastic properties). To combat these challenges, direct ink write (DIW) AM extrudes highly viscous composites by applying pneumatic backpressure to a syringe, such that the material can be extruded in ambient conditions. This method enables processing of unreacted, thermosetting resins which have been filled with a large proportion of solid particulate fillers, called "highly filled" inks. The interparticle network formed from particle-particle interactions in the form of weak surface forces (e.g. Van der Waals forces) provides structural stability of the printed lines, such that they can sustain the weight of subsequent layers. In the realm of DIW 3D printing material discovery and processing, there are currently three major challenges. First, the high shear region of the nozzle frequently disrupts the interparticle network through a de-agglomeration process, such that there is a finite timescale for the interparticle network to reestablish itself. During this timeframe, the deformation/reformation process causes printed lines to sag, which negatively impacts both print quality and mechanical properties. Second, printed parts require a post-processing step to develop adequate mechanical properties suitable for the final product. The kinetics of this cure process are extremely slow, often taking multiple days or weeks to reach completion. Third, high shear rheological characterization of highly filled inks is challenging because of the numerous artifacts of error associated with high shear testing environments (e.g. sample loss/edge fracture, slip, and large sample size requirements). A literature review in Chapter 2 outlines the most recent advances in highly filled polyurethane processing for DIW, with a particular focus on how interparticle network recovery – in the form of thixotropy – can be tailored using a variety of reactive inks. The subsequent chapters of this dissertation address these challenges by systematically downselecting reactive inks appropriate for highly filled DIW extrusion while introducing numerous process relevant rheological protocols. An initial discussion in Chapter 3 covers the potential drawbacks of thermoplastic polyurethane (TPU) processing as it relates to industrial scale melt extrusion. Specifically, multiple side reactions and degradation processes are identified for a variety of TPU manufacturers. Such reactions elicit undesirable solid-like particulate buildup within the extrusion line, and the impacts/causes of these reactions are quantified using rheological criteria. These protocols offer evidence that differences in processability can arise not just between manufacturers, but also between lots of TPU from the same manufacturer. To address these concerns, Chapter 4 offers an alternative form of polyurethane processing in the form of a thermosetting reaction between hydroxyl-terminated polybutadiene (HTPB) and isophorone diisocyanate (IPDI). When uncatalyzed at room temperature, full conversion takes place over the course of multiple weeks which necessitates an accelerated kinetic analysis. Hence, a combination of chemorheological and spectroscopic methods are used to rapidly probe for changes in isocyanate reactivity using limited sample quantities, which substantiate the advantages and disadvantages of chemorheology and spectroscopy in the context of curing studies. While this synthetic pathway provides mechanical properties appropriate for the final printed product, a major concern is retention of green body strength post deposition. In order to maintain the shape of printed beads, ultraviolet (UV) light can be shined in-situ onto the nozzle of a DIW printhead, which actively cures the urethane acrylate ink through free radical polymerization. This technique, termed UV-assisted direct ink write (UV-DIW), assists recovery of the interparticle network. A novel rheological method proposed in Chapter 5, termed the "UV-assisted three interval thixotropy test" (UV-3ITT), quantifies the contribution of UV light towards structural stability and printability. This is accomplished by applying stepwise changes in strain on a torsional photorheometer, optionally applying UV light in the third interval, and then quantifying the contribution of UV light towards process-relevant recovery parameters. Resultingly, the threshold of solid particulate fillers required for UV light to improve print fidelity is determined. While most discussions revolve around torsional rheology, this method has one major drawback: it cannot probe the high shear properties of high solids content materials due to sample loss/edge fracture during steady shear measurement. Capillary rheometers are able to probe the viscosity profiles of highly filled materials in high shear environments, but the cost of the device and the sample requirements are burdensome. To resolve this challenge, the "microcapillary rheometer" is developed in Chapter 6 using common laboratory equipment at a fraction of the cost of a full-scale capillary rheometer, which enables rapid characterization of high solids content materials at extrusion-relevant conditions while exploiting small sample quantities. This study illustrates the accuracy and precision of the microcapillary rheometer when comparing the high shear properties of several highly filled systems to the full-scale capillary rheometer. Results highlight that application of the Bagley and Weissenberg-Rabinowitsch corrections is possible using this novel device, which facilitates calculation of true shear viscosity of high solids content systems. The limited sample requirement facilitates characterization of novel or potentially hazardous materials in a much safer, efficient manner, which accelerates material discovery while improving safety standards. / Doctor of Philosophy / Subtractive manufacturing technologies, which reduce raw materials down from their bulk state into a final product, make up a significant portion of the manufacturing sector today due to the convenience and ease of material processing. Some of the most common forms of subtractive manufacturing include lathing, milling, cutting, drilling, and grinding; these methods are applicable for a diverse set of materials ranging from metals to plastics. By the nature of this process, subtractive manufacturing yields substantial material waste, while limiting the complexity of a final product's design. To combat these unintended consequences, a novel form of production termed additive manufacturing (AM) has grown dramatically in the past several decades. AM directly processes raw materials into their final form which reduces material waste while enabling complex geometries to be "printed." Although there are numerous types of additive manufacturing, the most common forms utilize material extrusion, whereby the raw material is deposited through a nozzle and stacked in a layer-by-layer fashion onto a build bed, thus constructing a final product. For materials that melt and flow at elevated temperatures (i.e. thermoplastic materials), fused filament fabrication (FFF) is ideal since a solid filament can be fed into a heated nozzle, melted onto a build bed, and then quickly re-solidified. However, many polymers do not melt at elevated temperatures, and instead degrade; these materials are termed "thermosetting." To print these materials, unreacted thermosetting precursors, which are filled with a large proportion of solid fillers ("highly filled inks"), can be extruded by applying pneumatic back pressure to a syringe at ambient conditions. The process of extruding these materials layer-by-layer describes the direct ink write (DIW) technique. The solid particulate fillers form structural "networks" due to weak electrostatic forces on the surface of the fillers. These forces provide structural stability and enable the printed lines to hold the weight of subsequent layers. Unfortunately, the high-pressure region of the nozzle disrupts this network, causing the printed lines to sag over time. This effect can be reduced by actively applying ultraviolet (UV) light onto the nozzle during extrusion, which helps to hold the particles in place by curing the resin, thus increasing the capacity for a line to sustain the weight of subsequent layers. This form of material extrusion is termed UV-assisted direct ink write (UV-DIW). Because UV light only partially cures the material during prints, a separate, slower thermosetting reaction can occur as the material rests in an oven or in ambient conditions, which completely cures the printed part and provides sufficient mechanical properties. The combination of UV-curable resins, thermosetting resins, and sufficiently large amounts of solid particulate fillers for material extrusion describes the dual-cure nature of this highly filled UV-DIW process. To understand the curing patterns, flow behavior, and the amount of structural deformation that occurs within the nozzle, rheology becomes a powerful characterization tool. This branch of physics deals with the deformation and flow of matter ranging from simple fluids to complex polymer melts. As such, it is possible to probe reaction progress (chemorheology), structural deformation/reformation (thixotropy), and high-shear regimes representative of the DIW process. The research contained within this dissertation provides a holistic understanding of the overlap between rheology and DIW material extrusion for dual-reactive materials. This process begins by evaluating challenges during melt extrusion of thermoplastic polyurethane while quantifying the rate of degradation side reactions. An alternative form of polyurethane synthesis in the form of a thermosetting reaction is then introduced, whereby the reaction progress is evaluated using both rheological and spectroscopic techniques. Next, a novel rheological protocol is introduced which can predict the structural deformation/reformation of an ink during UV-DIW. This research concludes by proposing a downscaled version of the high-shear capillary rheometer which requires only several grams of material in contrast to the dozens of grams required for full-scale capillary rheometry. In essence, the work presented here rapidly evaluates the complex flow behavior and cure progression of various materials relevant for extrusion processes by utilizing limited sample quantities, thus preserving valuable resources while improving the economics of material discovery.