SBIR Phase I: 3D Printing of Thermally Stable Composites for Injection Molding Tooling

这项小企业创新研究（SBIR）第一阶段项目的广泛影响/商业潜力将使Fortify能够为美国制造商提供颠覆性的制造技术，以创造小批量的工具零件，并在交货时间和零件价格方面降低数量级。美国制造商依赖于原型和小批量生产部件，这些部件目前使用铝制软模具生产，需要精密加工。根据复杂程度的不同，这些小零件的价格可以达到每件1万美元或更多，交货时间可以延长数周或数月。当小批量生产零件时，这导致了高单位成本。行业数据显示，外包原型和小批量注塑零件的市场规模可能高达27亿美元，这些零件的物理尺寸可通过Fortify技术进行维修。这个小企业创新研究第一阶段项目将使Fortify能够创造热竞争优势，使客户能够在小批量注塑模具领域发现。尽管3D打印领域的噪音很大，但由于3D打印模具对高强度、热稳定性、抗疲劳性和光滑的模具光洁度的持续需求，打破注塑模具行业仍然难以实现。Fortify是独特的定位，以解决这些技术挑战，利用新颖的材料，专利的制造硬件和专有的制造软件。Fortify打印陶瓷填充的高温树脂，这些树脂在定制的磁性打印机中通过磁场局部纹理，产生由Fortify的INFORM软件设计的最佳陶瓷微结构，以最大限度地提高打印部件的热机械性能。该奖项反映了美国国家科学基金会的法定使命，并通过使用基金会的知识价值和更广泛的影响审查标准进行评估，被认为值得支持。

The broader impact/commercial potential of this Small Business Innovation Research (SBIR) Phase I project will enable Fortify to provide U.S. manufacturers with a disruptive manufacturing technology to create low-volume tooling parts with order of magnitude reductions in lead times and part price. U.S. manufacturers rely on prototype and low-volume production parts that are currently produced using aluminum soft tooling that need to be precision machined. Prices for these small run parts can reach USD $10,000 or more per tool, depending on complexity, with lead times extending weeks or months. This results in high unit costs when parts are produced in low volumes. Industry data suggests the market for outsourced prototype and low volume injection molded parts with physical dimensions serviceable by Fortify technology may be as large as USD $2.7 Billion.This Small Business Innovation Research Phase I project will enable Fortify to create a thermal competitive advantage to enable customer discovery in the field of low-volume injection molding tooling. Despite the noise in the field of 3D printing, disrupting the injection molding tooling industry has remained elusive due to the lasting need for high strength, thermal stability, fatigue resistance, and smooth mold finish in 3D printed molds. Fortify is uniquely positioned to address these technical challenges by leveraging novel materials, patented manufacturing hardware, and proprietary manufacturing software. Fortify prints ceramic-filled, high-temperature resins that are locally textured by magnetic fields in customized magnetic printers to produce optimum ceramic microstructures designed by Fortify's INFORM software to maximize the thermomechanical performance of the printed parts.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.