SBIR Phase I: Novel Ultra-Rapid, High Definition, Additive Manufacturing System

这个SBIR第一阶段项目将研究一种新的超高速3D打印技术，旨在打破添加剂制造未来的重要障碍。该主题是一台机器和材质集，可以在高分辨率下提供指数级的更快的对象生成。该系统以一种新的方式利用了几项熟悉的技术，为3D打印提供了一条途径，通常被认为是为高科技行业预留的，使每个人都可以使用3D打印。由于新方法如此快速、详细，而且材料如此多样化，它有望在许多情况下通过消除模具成本来提高塑料制造的利润率。通过这种方式，许多被迫外包到海外的美国企业将能够维持国内生产，并增加制造业工作岗位返回美国。此外，耗材的制造也将增加就业机会。当这一新方法完全被采用时，它在医疗领域的使用将使拯救生命和提高生命的假体、植入物和药物测试应用程序更具成本效益，可以由联邦医疗保险提供资金，使我们所有的公民受益。通过为价值6000亿美元的普通塑料制造行业以及专业设计师、工程师、技术专业人员和医疗和科学界提供更高比例的服务，新系统的多种形式最终将使美国几乎每个行业受益，增加3D市场部门的增长和实用价值。这项发明的独特之处在于它同时使用了多个学科。作为一种固态系统，偏压建材压在玻璃屏幕上，玻璃屏幕是微孔的，带有与平板屏幕相同的电子设备。通常为视频图像保留的离散寻址，称为行和列刷新率，改为用于激活在这种开放式编织配置中产生微热点的阻性材料。热量刺激建筑材料穿过玻璃并在顶部固化，分辨率为1000 dpi，或每平方英寸100万个液滴。这些高分辨率的水滴结合在一起并冷却，因为一整层水以每秒30-120次的速度一次创建，没有机械头来回跟踪。这些物体看起来应该简单地以大约每分钟一到七英寸的垂直方向出现在玻璃上，这取决于刷新率，实际上是任何平面尺寸，并且可以立即使用，因为不需要后固化处理。集成激活的视频矩阵以一次构建整个横截面，可以指数级地提高速度。玻璃中的气孔依赖于已知的微流体科学，这是一种高度精细的移动整个2D液体基质的方法，以消除昂贵和缓慢的机械化，并将在这一应用中进行研究。已经为许多实施例开发了坚固和多样化的材料，并将对其进行测试。首先在多物理模拟中进行优化，然后在第一阶段构建一个简化的概念证明，这应该为在第二阶段继续进行这一新方法的工作提供令人信服的证据。

This SBIR Phase I project will examine a new ultra-rapid 3D printing technology designed to break down important barriers to the future of Additive Manufacturing. The subject is a machine and materials set that can provide exponentially faster object generation at high resolution. This system leverages several familiar technologies in a new way to provide a path for 3D printing, generally considered reserved for the high-tech sectors, to become accessible to everyone. Because the new method is so rapid, detailed, and the materials are so diverse, it is poised to enhance plastics manufacturing profit margins by eliminating mold costs in many cases. In this way, many American business forced to outsource overseas will be able to maintain domestic production and increase the return of manufacturing jobs to the US. In addition, the manufacturing of the consumables will also enhance job creation. When this new method is fully adopted, its use in the medical field will make lifesaving and life enhancing prosthetic, implantable, and pharmaceutical testing applications much more cost effective, fundable by Medicare, benefiting all our citizens. By servicing a higher percentage of the general plastics manufacturing $600B industry, as well as professional designers, engineers, technical professionals, and the medical and scientific community, the new system in its many forms will eventually be of benefit to nearly every industry in the US, increasing the growth and practical value of the 3D market sector.The subject invention is unique in its use of multiple disciplines simultaneously. As a solid-state system, pressure-biased build material presses up against a glass screen, which is micro-porous, and is laced with the same kind of electronics as are found in flat screen displays. The discrete addressing normally reserved for video images, known as row-and-column refresh rates, is instead used to activate resistive material generating micro-heat spots in this open weave configuration. The heat stimulates the build material to transit the glass and solidify topside, at 1000 dpi resolution, or 1 million droplets per square inch. These high-resolution droplets conjoin and cool, as an entire layer is created at once at 30-120 times a second with no mechanical heads tracking back and forth. The objects should seem to simply appear on the glass at about one to seven vertical inches per minute, depending on the refresh rate, at virtually any planar size, and can be used right away, since no post-curing treatment is needed. Integrating an activated video matrix to build entire cross sections at once, increases speed exponentially. The pores in the glass rely on the known science of Microfluidics, a highly refined means of moving an entire 2D matrix of liquid, to eliminate costly and slow mechanization, and will be studied in this application. Robust and diverse materials have been developed for many embodiments and will be tested. Optimizing first in Multiphysics simulation, and then fabricating a simplified Proof of Concept in Phase I, should provide compelling evidence for continued work on this novel method in Phase II.