SBIR Phase I: 3-D printing of high strength-to-weight closed-cell polymer foam with gyroid lattices

SBIR 第一阶段：3D 打印具有螺旋晶格的高强度重量比闭孔聚合物泡沫

• 批准号: 1938466
• 负责人: Matthew Pearlson
• 金额: $ 22.5万
• 依托单位: IGNEOUS IP HOLDINGS, LLC
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2019
• 资助国家: 美国
• 起止时间: 2019-10-15 至 2022-01-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1938466&HistoricalAwards=false
• 关键词: SBIR; Phase; printing; strength; weight

The broader impact/commercial potential of this Small Business Innovation Research (SBIR) Phase I project is to advance the state of the art of additive manufacturing, through development of a novel foam resin technology for rapid 3-D printing of ultra low-density parts with high strength-to-weight ratios. The demand for lightweight, high-strength printed parts is growing across all sectors of the manufacturing industry. The additive manufacturing market is expected to more than double by 2026, with high resolution vat photopolymerization as its largest market segment ($1 B). By accelerating production speeds and overcoming size limitations that have limited manufacturing output to small products, the technology also opens the doors for general manufacturing. Within the automotive, aviation and shipping industries, for example, the technology will support lightweighted designs, thus increasing efficiency, while lowering energy consumption, material consumption, and greenhouse gas emissions, resulting in lightweight printed parts.This Small Business Innovation Research (SBIR) Phase I project will develop a novel method to modify the high resolution vat photopolymerization process, to enable 3D printing with resin that is foamed using a patent-pending process. Because the proposed technology can be adapted for use on most vat photopolymerization systems, industries can apply it to their existing resins, machines, and processes. The technology will allow for the manufacture of lightweight parts with up to 75% gas fractions, translating to parts that are 75% lighter and less expensive to produce compared to traditional additive manufacturing processes. In order to establish proof-of-concept and progress the technology toward commercialization, several critical objectives must be met. Materials that can produce strong, lightweighted products using this technology will be identified. Different types of materials will be investigated in experiments designed to vary the gas fraction in the cured foam, and at least 3 resin formulations will be selected to generate foams for further evaluation of their mechanical properties. The results of three types of tests (compression, impact, and 3-point bending) on foams printed using the proprietary PrintFoam process will be compared to other materials to demonstrate that the technology delivers materials with improved strength-to-weight ratios. In addition, plans for scale-up of the machine and technology will be generated.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.

该小型企业创新研究 (SBIR) 第一阶段项目的更广泛影响/商业潜力是通过开发一种新型泡沫树脂技术，用于快速 3D 打印具有高强度重量比的超低密度零件，从而推进增材制造的最先进水平。制造业的各个领域对轻质、高强度打印零件的需求都在增长。 预计到 2026 年，增材制造市场将增长一倍以上，其中高分辨率还原光聚合将成为其最大的细分市场（$1 B）。 通过加快生产速度并克服限制小型产品制造产量的尺寸限制，该技术也为一般制造打开了大门。例如，在汽车、航空和航运行业，该技术将支持轻量化设计，从而提高效率，同时降低能源消耗、材料消耗和温室气体排放，从而生产出轻量化的打印零件。该小型企业创新研究 (SBIR) 第一阶段项目将开发一种新颖的方法来修改高分辨率还原光聚合工艺，以实现使用发泡树脂进行 3D 打印。 正在申请专利的工艺。由于所提出的技术可以适用于大多数还原光聚合系统，因此行业可以将其应用于现有的树脂、机器和工艺。 该技术将允许制造气体含量高达 75% 的轻质零件，与传统的增材制造工艺相比，零件重量减轻 75%，且生产成本更低。 为了建立概念验证并将技术推向商业化，必须满足几个关键目标。将确定使用该技术可以生产坚固、轻质产品的材料。将在旨在改变固化泡沫中气体分数的实验中研究不同类型的材料，并且将选择至少 3 种树脂配方来生成泡沫，以进一步评估其机械性能。使用专有 PrintFoam 工艺打印的泡沫的三种类型测试（压缩、冲击和三点弯曲）的结果将与其他材料进行比较，以证明该技术提供的材料具有更高的强度重量比。此外，还将制定扩大机器和技术规模的计划。该奖项反映了 NSF 的法定使命，并通过使用基金会的智力价值和更广泛的影响审查标准进行评估，被认为值得支持。