SBIR Phase I: Novel Ultra-Rapid, High Definition, Additive Manufacturing System

SBIR第一阶段项目将研究一种新的超快速3D打印技术，旨在打破未来增材制造的重要障碍。该主题是一个机器和材料集，可以提供高分辨率的指数更快的对象生成。该系统以一种新的方式利用了几种熟悉的技术，为3D打印提供了一条道路，通常被认为是为高科技行业保留的，每个人都可以使用。由于新方法是如此快速，详细，材料是如此多样，它有望通过消除模具成本在许多情况下提高塑料制造的利润率。通过这种方式，许多被迫将业务外包到海外的美国企业将能够维持国内生产，并增加制造业工作岗位回流美国。此外，消费品的制造也将促进创造就业机会。当这种新方法被完全采用时，它在医疗领域的使用将使挽救生命和提高生命的假肢，植入式和药物测试应用更具成本效益，由医疗保险资助，使我们所有的公民受益。通过为6000亿美元的通用塑料制造业以及专业设计师，工程师，技术专业人员以及医疗和科学界提供更高比例的服务，新系统的多种形式最终将使美国几乎所有行业受益。增加3D市场部门的增长和实用价值。本发明的独特之处在于它同时使用多个学科。作为一个固态系统，压力偏置的构建材料压在玻璃屏幕上，玻璃屏幕是微孔的，并且与平面屏幕显示器中发现的电子设备相同。通常为视频图像保留的离散寻址（称为行和列刷新率）被用于激活电阻材料，从而在这种开放编织配置中产生微热点。热量刺激构建材料以1000 dpi分辨率或每平方英寸100万个液滴通过玻璃并固化顶面。这些高分辨率的液滴结合并冷却，因为整个层以每秒30-120次的速度一次性创建，没有机械头来回跟踪。物体应该看起来简单地出现在玻璃上，大约每分钟1到7英寸，这取决于刷新率，几乎任何平面尺寸，并且可以立即使用，因为不需要后固化处理。集成一个激活的视频矩阵，一次构建整个横截面，以指数方式提高速度。玻璃中的孔依赖于已知的微流体科学，这是一种移动整个2D液体矩阵的高度精细的手段，以消除昂贵和缓慢的机械化，并将在本申请中进行研究。已经为许多实施例开发了坚固且多样的材料，并且将对其进行测试。首先在多物理场模拟中进行优化，然后在第一阶段制作一个简化的概念验证，应该为第二阶段继续研究这种新方法提供令人信服的证据。

This SBIR Phase I project will examine a new ultra-rapid 3D printing technology designed to break down important barriers to the future of Additive Manufacturing. The subject is a machine and materials set that can provide exponentially faster object generation at high resolution. This system leverages several familiar technologies in a new way to provide a path for 3D printing, generally considered reserved for the high-tech sectors, to become accessible to everyone. Because the new method is so rapid, detailed, and the materials are so diverse, it is poised to enhance plastics manufacturing profit margins by eliminating mold costs in many cases. In this way, many American business forced to outsource overseas will be able to maintain domestic production and increase the return of manufacturing jobs to the US. In addition, the manufacturing of the consumables will also enhance job creation. When this new method is fully adopted, its use in the medical field will make lifesaving and life enhancing prosthetic, implantable, and pharmaceutical testing applications much more cost effective, fundable by Medicare, benefiting all our citizens. By servicing a higher percentage of the general plastics manufacturing $600B industry, as well as professional designers, engineers, technical professionals, and the medical and scientific community, the new system in its many forms will eventually be of benefit to nearly every industry in the US, increasing the growth and practical value of the 3D market sector.The subject invention is unique in its use of multiple disciplines simultaneously. As a solid-state system, pressure-biased build material presses up against a glass screen, which is micro-porous, and is laced with the same kind of electronics as are found in flat screen displays. The discrete addressing normally reserved for video images, known as row-and-column refresh rates, is instead used to activate resistive material generating micro-heat spots in this open weave configuration. The heat stimulates the build material to transit the glass and solidify topside, at 1000 dpi resolution, or 1 million droplets per square inch. These high-resolution droplets conjoin and cool, as an entire layer is created at once at 30-120 times a second with no mechanical heads tracking back and forth. The objects should seem to simply appear on the glass at about one to seven vertical inches per minute, depending on the refresh rate, at virtually any planar size, and can be used right away, since no post-curing treatment is needed. Integrating an activated video matrix to build entire cross sections at once, increases speed exponentially. The pores in the glass rely on the known science of Microfluidics, a highly refined means of moving an entire 2D matrix of liquid, to eliminate costly and slow mechanization, and will be studied in this application. Robust and diverse materials have been developed for many embodiments and will be tested. Optimizing first in Multiphysics simulation, and then fabricating a simplified Proof of Concept in Phase I, should provide compelling evidence for continued work on this novel method in Phase II.