Yu, Siwon Park, Seunggyu Kang, Dae Young Shin, Geun Sik Lee, Min Wook Moon, Sook Young Hwang, Jun Yeon 2024-01-19T09:03:46Z 2024-01-19T09:03:46Z 2023-09-07 2023-07 1359-8368 https://pubs.kist.re.kr/handle/201004/113485 Metal-plastic hybrids are emerging as a new challenge in multi-material 3D printing. Here, we provide a novel printing method for strategically bonding and printing metal-plastic hybrids using dual lasers with different wavelengths in a single integrated process. This bottom-up process enables three-dimensional freeform deposition while creating an ideal metal-plastic interface. In particular, our research has shown that the strategic selection of a laser with high energy absorption efficiency for the target material is a key technology for material hybridization. It was revealed that the laser, when irradiated directly onto the interface, partially crosslinks the plastic to form dense phases and induces a chemical reaction with oxygen active species on the metal surface, e. g., an intermediate oxide layer of Al-O-C, leading to the formation of a strong metal-plastic interface. Interestingly, this laser-induced metal-plastic interface, sophisticatedly controlled at the monolayer thickness level, exhibited a distinctive near-interface failure mechanism that developed crack paths along the near interface. Moreover, the competition between crack propagation and pore coalescence in each dense and porous printed layer formed a synergetic interphase, resulting in strong and tough mechanical functions. Our findings can guide the development of metal-plastic hybrids for a variety of industrially important applications. English Pergamon Press Ltd. Strategic dual laser 3D printing of structural metal-plastic hybrid materials Article 10.1016/j.compositesb.2023.110794 1 Composites Part B: Engineering, v.261 Composites Part B: Engineering 261 N scie scopus 001053230400001 2-s2.0-85159230879 Engineering, Multidisciplinary Materials Science, Composites Engineering Materials Science Article JOINTS MECHANISM BEHAVIOR Multi-material 3D printing Metal -plastic hybrids Laser-induced metal -plastic interface Near-interface failure mechanism