Fine Metal Powders

Metal additive manufacturing utilizes fine metal powders to construct robust, intricate components through computer-aided design (CAD) programs or 3D scanning, say sources from IIT Mandi.

This layer-by-layer manufacturing process offers flexibility in designing complex structures, finding applications in diverse industries such as aerospace, automotive, spare parts, heat sinks, biomedical devices, and construction materials, say sources from IIT Mandi.

They have meticulously detailed the extrusion-based process, termed mFFF/FDMet (metal fused filament fabrication/fused deposition of metals), in their publication in the journal Composites Part B.

Real-life application

Explaining the real-life application of the research, Mr. Naveen Kumar Bankapalli, Research Scholar, IIT Mandi, said, “This analysis empowers individuals, industries, or researchers to independently develop and implement this technology, facilitating cost-effective mass production of metal parts.

Particularly noteworthy for aerospace applications due to its lightweight nature, the extrusion-based process outshines current metal additive manufacturing alternatives, said Naveen Kumar of IIT Mandi.

Popular

While Powder Bed Fusion (PBF) and Direct Energy Deposition (DED) are popular metal additive manufacturing technologies, the extrusion-based method distinguishes itself by being more cost-effective, less hazardous, and offering greater design freedom, say sources from IIT Mandi.

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Employing unique filaments composed of polymeric additives and metal powder, the mFFF/FDMet technique allows for versatile shaping and avoids the hazards associated with fine metal powders in PBF and DED processes, say sources from IIT Mandi.

Despite its lengthier process, it proves more economical for mass production of metal parts, in comparison to the conventional methods.

This underscores the need for an accessible additive manufacturing system capable of producing metal samples quickly, inexpensively, and creatively, say sources from IIT Mandi.

Importance

While stressing the importance of adopting this novel technology, Dr. Prateek Saxena, Assistant Professor, School of Mechanical & Materials Engineering, IIT Mandi, said, currently, only foreign companies dominate this entire process, creating a monopoly.

Our aim is to empower potential producers with a thorough understanding of the process, enabling independent development of the technology, said Dr Prateek Saxena.

Momentum

The global metal 3D printing industry is gaining momentum, evident in initiatives like the US Air Force’s second AM lab for aircraft parts and Indian steel giants entering the fray.

Recognizing the potential of additive manufacturing, the Indian government is committed to developing indigenous products for various sectors.

Designed to monitor the freshness of seafood in real-time by responding to pH changes, the film offers a practical solution for improving food safety and reducing waste.

This film detects the release of volatile amines, compounds typically associated with spoilage, and indicates food quality through visible color changes, say sources from NIT Rourkela.

These natural components make the film biodegradable, safe, and responsive, aligning with sustainability goals and offering a non-invasive way to assess seafood freshness.

Findings

The findings of this research have been published in the journal Food Packaging and Shelf Life in a paper co-authored by Prof. Preetam Sarkar (as the lead corresponding author), along with his research scholars, Mr. Rahul Thakur, Miss Harshi Singhi, Mr. Vedsagar Rajesh Suryavanshi, and Dr. Ravichandran Santhosh.

Other co-authors in this work include Dr. Khalid Gul from NIT Rourkela, Dr. Swarup Roy from Lovely Professional University, Dr. Srinivas Janaswamy from South Dakota State University, Brookings, USA and Dr. Kirtiraj K. Gaikwad from IIT Roorkee.

Fishing

India is the world’s second-largest fish-producing nation, contributing approximately 8% of global fish production, say NIT Rourkela researchers.

It also holds the distinction of being the top five producer of shrimp globally, with frozen shrimp being the top export commodity.

Given the scale and importance of seafood production, innovations that ensure freshness and reduce spoilage are of immense value, say NIT Rourkela researchers.

In this context, intelligent packaging systems, which preserve food while monitoring its quality, are rapidly gaining global interest.

Unlike conventional packaging that serves merely as a protective barrier, the intelligent packaging film developed by NIT Rourkela team offers visual cues about the product’s condition, making it a promising solution for enhancing food safety and reducing waste.

The beetroot peel extract was prepared separately, and then combined with the starch, gum tragacanth, and a small amount of glycerol to cast the films.

These were dried and tested for their pH-sensitivity and effectiveness in monitoring seafood freshness, said Prof Preetam of NIT Rourkela.

Pigments

Beetroot peels contain betalains, a group of pigments known for their bright colours and pH sensitivity, say NIT Rourkela researchers.

These pigments also offer antioxidant and antimicrobial benefits, making them suitable for food-related applications.

Incorporating these natural compounds into the starch-based film creates a biodegradable, safe, and responsive packaging material.

When the seafood begins to spoil and pH levels rise, the film changes colour, providing a clear visual indicator of freshness.

Starch

The choice of Kodo millet starch and gum tragacanth contributes to the film’s biodegradable and eco-friendly profile.

Kodo millet is an underutilised grain with excellent film-forming properties, while gum tragacanth enhances the mechanical strength and flexibility of the material.

The researchers believe that using such agricultural by-products not only supports sustainability but also adds value to food processing waste, such as beetroot peels.

At the laboratory scale, the cost of producing the film was estimated approximately Rs. 900 per kilogram.

When scaled up for industrial production, the cost is projected to range between Rs. 400 and Rs. 600 per kilogram, making it a potentially viable option for commercial use.

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