We present a multi-material rapid prototyping technique for producing 2D and layered 3D meso- and micro-structured multi-functional devices with spatially varying heterogeneous material compositions. This technique involves direct-write deposition of multiple, patterned powder materials followed by laser sintering. The direct-write deposition system features miniature hopper-nozzles for depositing dry powdered materials by gravity or by high frequency vibration-assisted flow on to a movable substrate. Deposition of 10-125μm powder particles via 100μm-2mm hopper-nozzles orifices has yielded a 100μm minimum attainable feature size for device footprints ranging from sub-millimeter to a few centimeters. The feasibility of this direct-write concept was proved by patterning single and multiple materials onto substrates to demonstrate various prototype devices envisaged by this technique. These include micro-battery, interdigitated capacitor, fractal antenna, Swiss-roll microcombustor, and functionally graded polymeric bioimplants.
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