I-Corps Teams: Energy efficient 3D printing of thermoset polymer and composites for field operations

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The broader impact/commercial potential of this I-Corps project will be the development of a 3D printing technology that has great potential in diverse applications, including oil/gas, renewable energy, aerospace, defense, and healthcare. In particular, readily usable parts fabricated using this 3D printing technology may be vital in supporting motorized equipment for field operations. This application holds true for commercial field operations that are situated in remote outposts with limited energy input. This project will advance 3D printing technology of thermoset polymer and composites and provide insights on developing more energy efficient, high-rate and end-user friendly advanced manufacturing techniques, ultimately benefiting society by saving energy and reducing design/fabrication cycles in mass production. This I-Corps project is based on the development of technology for a high-rate and energy-efficient 3D printing technology for thermoset polymer and composites that allows for fabrication of readily usable products for on-site operations and extreme conditions. The proposed innovation is an in-situ polymerization-based new additive manufacturing method using only heat or light initiation. The major concerns for conventional 3D printing technology such as high-energy consumption, negative environmental impact, and low production rate will be addressed. It combines the cutting-edge research in materials science/engineering, mechanical engineering, computer science and cyber systems. Using the thermoset polymers and their composites, the as-printed products are designed to demonstrate improved temperature and shape stability with negligible environmental impact.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.