SBIR Phase I: Innovative Selective Laser Sintering Rapid Manufacturing Technique Using Nanotechnology

这个小型企业创新研究(SBIR)第一阶段项目将使用一种快速制造方法来生产高性能结构部件。这一过程将结合纳米技术和选择性激光烧结(SLS)，以及快速成型(RP)附加分层构建制造方法。SLS快速成型技术的使用将有助于真正、灵活地制造小批量零件，同时避免生产线工具、熟练劳动力利用率低下和维护高额管理设施成本的需要。SLS快速制造方法将促进准时制造和精益制造的概念。目前用于激光烧结的热塑性聚合物粉末(尼龙11或尼龙12)缺乏阻燃和高强度/高耐热特性。预计尼龙11的纳米化将使尼龙11具有预期的聚合物性能特征，即耐火、高强度和高耐热性，并将扩大SLS用户和尼龙11树脂制造商的市场机会。这项技术的更广泛影响可能是一种独特的低比重聚合物粉末(尼龙11)，这种粉末具有防火、高强度和高耐热性，通常需要大量阻燃添加剂以及大量增强剂和添加剂。纳米颗粒的使用避免了使用危险的阻燃添加剂，如卤化或氮/磷材料，所有这些材料在燃烧时都会产生烟雾和毒性。与20%至30%的常规无机填料(玻璃纤维、矿物纤维等)相比，使用少量的纳米颗粒(~7%)可提供足够的强度和耐热性。纳米颗粒的多功能特性可以导致低比重聚合物粉末，并在成品零件制造中大幅减轻重量。这种新的快速制造方法将受到有资格为美国国防工业提供零部件的SLS用户的极大欢迎。通过及时、无缝的采购机制为老化的遗留武器系统快速、经济地提供备件的能力可以产生巨大的成本节约。

This Small Business Innovation Research (SBIR) Phase I project will use a rapid manufacturing method to produce high performance structural components. This process will combine nanotechnology with Selective Laser Sintering (SLS), and a Rapid Prototyping (RP) additive layered build fabrication method. The use of SLS RP technique will facilitate true, flexible manufacturing of small batch of parts, while avoiding product-line tooling, under utilization of skilled labor and the need to maintain high overhead facilities costs. The SLS rapid manufacturing method will contribute to the concept of just in time manufacturing as well as lean manufacturing. Current thermoplastic polymer powders (Nylon 11 or Nylon 12) used in SLS are lacking in fire resistance and high strength/high heat resistance characteristics. It is anticipated that nanomodification of Nylon 11 will result in the expected polymer performance characteristics, i.e., fire resistance, high strength and high heat resistance for Nylon 11 and will expand the market opportunities for SLS users and Nylon 11 resin manufacturers. The broader impacts from this technology could be an unique, low specific gravity polymer powders (Nylon 11) that are fire-resistant, possess high strength and high heat resistance that ordinarily require large amounts of flame retardant additives as well as large amounts of reinforcing agents, and additives. The use of nanoparticles avoids the use of hazardous flame retardant additives such as halogenated or nitrogen/phosphorous materials, all of which contribute to smoke and toxicity when burning. Use of small amounts of nanoparticles (~7%) provides sufficient strength and heat resistance as compared to 20 to 30% conventional inorganic filler (glass fiber, mineral fiber, etc). The multifunctional characteristics of the nanoparticles could lead to low specific gravity polymer powders and substantial weight savings in finished part fabrication. This new rapid manufacturing method will be greatly embraced by SLS users who are qualified to provide parts to the U.S. Defense Industry. The ability to quickly and economically provide spare parts for aging legacy weapon systems through a seamless procurement mechanism of just in time could produce enormous cost savings.