Hierarchical porous metals with deterministic 3d morphology and shape via de-alloying of 3d printed alloys

A system for forming a three dimensional, hierarchical, porous metal structure with deterministically controlled 3D multiscale hierarchical pore architectures, the system comprising:

• a printing stage;
• an additive manufacturing system including a processor having a nozzle, and configured to print a three dimensional (3D) structure in a layer-by-layer process by flowing a rheologically tuned ink through the nozzle onto the printing stage and to build up the 3D structure in a layer-by-layer;
• an annealing subsystem configured to anneal the 3D structure to remove the binder, and to form an alloyed 3D structure;
• and
• a de-alloying subsystem configured to de-alloy the alloyed 3D structure to form a hierarchical, nanoporous 3D structure having an engineered, digitally controlled macropore morphology with integrated nanoporosity.

A system for forming a three dimensional, hierarchical, porous metal structure with deterministically controlled 3D multiscale hierarchical pore architectures, the system comprising:

• a printing stage;
• a rheologically tuned, flowable ink including a metal powder and a binder;
• an additive manufacturing system including a processor for controlling a printing process, and also having a nozzle, and configured to print a three dimensional (3D) structure in a layer-by-layer process by flowing the rheologically tuned ink through the nozzle onto the printing stage, to build up the 3D structure in a layer-by-layer printing operation;
• an annealing subsystem configured to anneal the 3D structure by heating the 3D structure for a predetermined time period to remove the binder, to form an alloyed 3D structure;
• and
• a de-alloying subsystem configured to de-alloy the alloyed 3D structure to form a hierarchical, nanoporous 3D structure having an engineered, digitally controlled macropore morphology with integrated nanoporosity.