SBIR Phase I: High Efficiency Robocasting for Ceramic Product Application

小企业创新研究（SBIR）第一阶段项目名为？高效机械铸造在陶瓷产品中的应用？旨在改进一种独特的增材制造工艺，称为机器人铸造，用于大规模生产下一代陶瓷催化剂支撑，这对汽车和清洁能源发电行业非常有用。特别是，大型先进的陶瓷催化剂支撑可以有效地将天然气转化为清洁燃料。目前，机器铸造可用于制造具有复杂几何形状的高级催化剂支撑；由于制造后的开裂问题，该技术一直局限于相对较小的部件。该项目将先进的陶瓷加工方法与微波辅助干燥和烧结技术相结合，以生产具有竞争力的工业规模的陶瓷催化剂载体，并提高其性能。研究将会完成，以减少因开裂而造成的限制，降低能源消耗，并提高自动化程度，从而为先进技术开辟一个新的市场，在全球范围内具有成本竞争力。该项目的广泛影响/商业潜力包括：1)对清洁能源应用的优化催化剂支持的科学理解，以帮助满足对汽车和工厂排放更严格的环境控制的需求；2)微波技术在工业制造中节能减排的应用；3)在美国本土创造制造业和stem相关的就业机会；4)增材制造技术的进步使美国在外国竞争中领先一步。

This Small Business Innovation Research (SBIR) Phase I project entitled ?High Efficiency Robocasting for Ceramic Product Application? is intended to improve a unique additive manufacturing process called robocasting for the large-scale production of next-generation ceramic catalyst supports useful to automotive and clean-energy-generation industries. In particular, large advanced ceramic catalyst supports could be an enabling technology for the efficient conversion of natural gas into clean fuels. Currently, robocasting can be used to fabricate advanced catalyst supports with intricate geometries however; the technology has been limited to relatively small components because of problems associated with cracking after fabrication. This project will combine advanced ceramic processing methods with microwave-assisted drying and sintering technology to competitively manufacture industrial-sized ceramic catalyst supports with improved performance. Research will be completed to reduce limitations due to cracking, reduce energy consumption, and improve automation with the result being a new market for an advanced technology that will be cost competitive throughout the world.The broader impact/commercial potential of this project has implications for:1) the scientific understanding of optimized catalyst supports for clean-energy applications to help meet demands for tighter environmental controls on automotive and plant emissions;2) the utilization of microwave technology for energy savings and reduced greenhouse gas emissions in industrial manufacturing;3) the creation of manufacturing and STEM-related jobs on US soil; and4) the advancement of additive manufacturing technology to keep the US a step ahead of foreign competition.