Projects

ARTIST - Advanced Runway Texture Imitations for Specialized Tiles Fabrication via Selective Laser Melting

We have chosen Laser Powder Bed Fusion (LPBF) technology to create highly accurate replicas of runway surfaces for aircraft tire testing. Additive Manufacturing (AM) of test tiles presents a unique opportunity for rapid production of realistic runway surface replicas. Additionally, AM provides production stability as the government can either own the equipment or outsource tile fabrication, giving control over the production process.

Our research team has successfully demonstrated that LPBF can be utilized to fabricate test tiles that accurately mimic the texture of runway surfaces. We have created 3x3 inch versions of these test tiles using Inconel 718 and AlSi10Mg alloys, comparing them to scans of actual runways to confirm the close resemblance in surface texture.

This advancement is highly advantageous for customers as test tiles produced through LPBF can replicate any runway surface with precision, surpassing the performance of traditional concrete materials. They are also easy to manufacture, making them a valuable asset for aircraft tire testing. This approach eliminates the necessity for costly manufacturing partnerships with specialty concrete suppliers, resulting in decreased expenses, quicker timelines, and reduced risks throughout both the testing setup phase and the complete testing program.

PhLAME - Pyrotechnic Hybridized Layouts via Advanced Manufacturing of Energetics

An innovative project was undertaken to utilize Additive Manufacturing for creating hybridized flare grains. Our unique method involved modifying existing pyrotechnic compositions to make them compatible with additive manufacturing, resulting in the production of core-shell flare grains. We were able to achieve tailored spectral signatures and unique burning characteristics that were previously unattainable with traditional production methods. Through extensive testing, we demonstrated the exceptional performance and versatility of our flare grains in terms of composition and energy payload. This technology offered precise control over material layering and electromagnetic signatures, providing unparalleled customization opportunities.

EPIC - Enhancing Performance via Innovative Coatings of AM Parts

The focus of the project was to create new protective coatings to 3D printed plastic parts in order to improve their strength, durability, hardness, and heat resistance. Initial findings from applying standard plating solutions to plastic parts printed using FFF and Vat Photopolymerization showed promising results, with noticeable differences in the appearance of the coated components. Despite not performing any pre-processing steps before coating, the coatings were found to be evenly distributed even in the recessed areas. This demonstrates the potential for our electroless plating approach to significantly enhance the properties of plastic AM components.

Metal Production Away from Earth

The overall goal of this project was to demonstrate the feasibility of selectively reducing metal oxides and extracting pure compounds to produce metals in a form and purity suitable for use in metal Additive Manufacturing. All of this while operating under extraterrestrial conditions and not consuming any reagents that are not regenerated as part of the process.

We carried out initial tests on metal oxides (NiO and Fe2O3) and succeeded in achieving nearly 100% conversion of oxide to elemental metal for both Ni and Fe after fine-tuning our processing conditions. This success paved the way for us to demonstrate similar conversion rates with Mars Regolith Simulant, proving the feasibility of extracting pure metals from Lunar and Martian Regolith.

CAPE - Component Authentication via Provenance Encasing for Additive Manufacturing

In this project, the primary focus was on creating a method to seamlessly embed covert security "barcodes" into additive manufacturing (AM) parts to prevent tampering risks. The process of integrating these "barcodes" is adaptable to all AM techniques and does not necessitate any changes to the existing processes or materials. The validation of parts is quick, secure, and accurate without causing any damage.

A total of 213 specimens were meticulously worked on, resulting in the successful embedding of "barcodes" into various components including ABS, clear and black acrylic, stainless steel, and Ti64 materials. The detection of these "barcodes" was flawless for both plastic and metal parts. It was found that post-curing affected the detection of the "barcode" for clear acrylic, but not for black. These findings were substantiated by simulations, confirming the experimental results. Most importantly, the integrity of the parts remained intact in the presence of the "barcode".

NEOSAFE – Novel Material for Manufacturing of Neonatal Devices via 3D Printing

The goal of this project was to design 3D printable polymer formulations tailored for the production of devices specifically catered to neonatal care. The developed formulation offered a multitude of advantages, including biocompatibility, sterilizability, and mechanical durability.

By employing vat photopolymerization, we were able to precisely configure the design of these devices, ensuring optimal performance and functionality. Our testing process has demonstrated that the developed formulation successfully withstands sterilization procedures without compromising its mechanical integrity. Moreover, the biocompatibility of the strongest cured formulations has been confirmed, earning them a grade “0” as per the ISO 10993 standard.

HAMMER – Hybridized Additive Manufacturing Machine with Error Rectification

The project goal was to design and build a multi-material AM machine that could handle polymer, metal, and ceramic materials simultaneously. We successfully demonstrated the system's ability to process a wide range of polymers (with varying melting temperatures, ranging from 135°C to over 300°C), achieving 99% density with Polyamide 6 as the base material. In addition, we showed the machine's capability to sinter metals like copper and iron, with part densities ranging from 80% to 90%. By utilizing an alternative operation mode, we were able to fabricate near 100% dense metallic parts. Our single two-dimensional feedback system proved to be highly effective, with error correction down to an impressive 8.5 µm±1.5 µm.

3D Printed Clothing Ensembles for The Next Generation Navy Uniform

The main objective of the project was to create polymeric materials suitable for FFF processing and to meet the physical performance standards of military textiles. Our focus was on developing innovative nylon-based polymer formulations and intelligent printing designs to enhance flexibility and comfort for 3D printing military garments. Through the use of FFF, we successfully produced clothing that not only met the necessary performance requirements but also provided optimal comfort properties.