In-process laser heating technique delivers a cost-efficient way to improve mechanical and geometrical properties to nearly isotropic and extremely smooth, respectively. The technique involves the incorperation of a solid-state laser into a commercial off-the-shelf 3D printer, mechanical system to allow controllable laser allumination on desired surfaces, and a gcode postprocesser to proper control of the mechanical system. This process uses laser for local heating, to enhance mass transfer between boundaries or to enhance surface reflow to smooth surface irregularity, to improve mechanical and geometrical properties. Only less than 3 W of laser power (CO2 laser) was used for high temperature material like PEEK and Ultem; less than 1 W (808nm laser) was found to be sufficient for achieving optimal properties for PLA. This technique has the potential for after-market integration into most commercial FFF 3D printers to achieved nearly isotropic and smooth 3D printed objects with various thermoplastic polymers.

This Project Report documents the accomplishments of an extraordinary group of students, faculty, and staff at the Arizona state University, who participated in a year-long, multidisciplinary, first-of-its-kind academic endeavor entitled “The Making of a COVID Lab.” The lab that is the focus of this project is the ASU Biodesign Clinical Testing Laboratory, known simply as the ABCTL.