SBIR Phase I: High Efficiency Robocasting for Ceramic Product Application

该小型企业创新研究(SBIR)第一阶段项目名为？陶瓷产品应用的高效机器人铸造？旨在改进一种称为机器人铸造的独特添加剂制造工艺，用于大规模生产对汽车和清洁能源发电行业有用的下一代陶瓷催化剂支撑件。特别是，大型先进陶瓷催化剂载体可能是将天然气有效转化为清洁燃料的一种使能技术。目前，机器人铸造可以用来制造具有复杂几何形状的先进催化剂载体；由于制造后与破裂相关的问题，这项技术仅限于相对较小的部件。该项目将先进的陶瓷加工方法与微波辅助干燥和烧结技术相结合，以具有竞争力的方式制造性能更好的工业尺寸陶瓷催化剂载体。该项目的广泛影响/商业潜力包括：1)科学地理解清洁能源应用的优化催化剂载体，以帮助满足对汽车和工厂排放进行更严格的环境控制的需求；2)利用微波技术在工业制造中节约能源和减少温室气体排放；3)在美国本土创造制造业和STEM相关的就业机会；以及4)发展添加剂制造技术，使美国在外国竞争中保持领先地位。

This Small Business Innovation Research (SBIR) Phase I project entitled ?High Efficiency Robocasting for Ceramic Product Application? is intended to improve a unique additive manufacturing process called robocasting for the large-scale production of next-generation ceramic catalyst supports useful to automotive and clean-energy-generation industries. In particular, large advanced ceramic catalyst supports could be an enabling technology for the efficient conversion of natural gas into clean fuels. Currently, robocasting can be used to fabricate advanced catalyst supports with intricate geometries however; the technology has been limited to relatively small components because of problems associated with cracking after fabrication. This project will combine advanced ceramic processing methods with microwave-assisted drying and sintering technology to competitively manufacture industrial-sized ceramic catalyst supports with improved performance. Research will be completed to reduce limitations due to cracking, reduce energy consumption, and improve automation with the result being a new market for an advanced technology that will be cost competitive throughout the world.The broader impact/commercial potential of this project has implications for:1) the scientific understanding of optimized catalyst supports for clean-energy applications to help meet demands for tighter environmental controls on automotive and plant emissions;2) the utilization of microwave technology for energy savings and reduced greenhouse gas emissions in industrial manufacturing;3) the creation of manufacturing and STEM-related jobs on US soil; and4) the advancement of additive manufacturing technology to keep the US a step ahead of foreign competition.