SBIR Phase I: Innovative Selective Laser Sintering Rapid Manufacturing Technique Using Nanotechnology

这个小企业创新研究（SBIR）第一阶段项目将使用快速制造方法来生产高性能的结构部件。该工艺将纳米技术与选择性激光烧结（SLS）和快速成型（RP）添加剂层状制造方法相结合。SLS RP技术的使用将促进小批量零件的真正、灵活的制造，同时避免生产线工装、熟练劳动力的利用和维持高间接设施成本的需要。SLS快速制造方法将有助于准时制造和精益制造的概念。目前用于SLS的热塑性聚合物粉末（尼龙11或尼龙12）缺乏耐火性和高强度/高耐热性。预计尼龙11的纳米改性将产生预期的聚合物性能特征，即尼龙11的耐火、高强度和高耐热性，并将扩大SLS用户和尼龙11树脂制造商的市场机会。这项技术的广泛影响可能是一种独特的、低比重的聚合物粉末（尼龙11），它具有耐火、高强度和高耐热性，通常需要大量的阻燃剂添加剂以及大量的增强剂和添加剂。纳米粒子的使用避免了使用有害的阻燃添加剂，如卤化或氮/磷材料，所有这些都会在燃烧时产生烟雾和毒性。使用少量的纳米颗粒（~7%）提供足够的强度和耐热性相比，20%至30%的传统无机填料（玻璃纤维，矿物纤维等）。纳米颗粒的多功能特性可以导致低比重聚合物粉末和成品零件制造的大量重量节省。这种新的快速制造方法将受到有资格为美国国防工业提供零件的SLS用户的极大欢迎。通过无缝的及时采购机制，快速经济地为老化的遗留武器系统提供备件的能力可以产生巨大的成本节约。

This Small Business Innovation Research (SBIR) Phase I project will use a rapid manufacturing method to produce high performance structural components. This process will combine nanotechnology with Selective Laser Sintering (SLS), and a Rapid Prototyping (RP) additive layered build fabrication method. The use of SLS RP technique will facilitate true, flexible manufacturing of small batch of parts, while avoiding product-line tooling, under utilization of skilled labor and the need to maintain high overhead facilities costs. The SLS rapid manufacturing method will contribute to the concept of just in time manufacturing as well as lean manufacturing. Current thermoplastic polymer powders (Nylon 11 or Nylon 12) used in SLS are lacking in fire resistance and high strength/high heat resistance characteristics. It is anticipated that nanomodification of Nylon 11 will result in the expected polymer performance characteristics, i.e., fire resistance, high strength and high heat resistance for Nylon 11 and will expand the market opportunities for SLS users and Nylon 11 resin manufacturers. The broader impacts from this technology could be an unique, low specific gravity polymer powders (Nylon 11) that are fire-resistant, possess high strength and high heat resistance that ordinarily require large amounts of flame retardant additives as well as large amounts of reinforcing agents, and additives. The use of nanoparticles avoids the use of hazardous flame retardant additives such as halogenated or nitrogen/phosphorous materials, all of which contribute to smoke and toxicity when burning. Use of small amounts of nanoparticles (~7%) provides sufficient strength and heat resistance as compared to 20 to 30% conventional inorganic filler (glass fiber, mineral fiber, etc). The multifunctional characteristics of the nanoparticles could lead to low specific gravity polymer powders and substantial weight savings in finished part fabrication. This new rapid manufacturing method will be greatly embraced by SLS users who are qualified to provide parts to the U.S. Defense Industry. The ability to quickly and economically provide spare parts for aging legacy weapon systems through a seamless procurement mechanism of just in time could produce enormous cost savings.