SBIR Phase I: Carbon Fiber Encapsulated Polymer Powder for Additive Manufacturing Advancements

这个小型企业创新研究（SBIR）第一阶段项目的更广泛的影响/商业潜力涉及适用于一系列工艺的短纤维增强热塑性材料的新生产，以及利用高质量，低成本回收或回收纤维的额外好处。滩头阵地应用是基于粉末的增材制造系统，能够进行中等规模的制造，可以在原型阶段和资本密集型注塑成型的规模经济制造之间架起桥梁。这些系统可以位于区域生产中心，以加速新产品或高度定制的产品推向市场。在这些系统中加入拟议的添加剂将扩大可用的最终产品材料特性范围，从而扩大同一平台的潜在客户群。该材料的预期流动特性将使其成为其他3D打印技术以及更大的注塑加工市场的可访问添加剂选项。这个小型企业创新研究（SBIR）第一阶段项目采用了尚未开发的加工技术，用于生产聚合物粉末原料3D打印的复合热塑性添加剂。这种添加剂有望增加最终产品的刚度、强度和热稳定性，同时减轻重量并在生产过程中提供相对于现有替代品的上级处理特性。该项目的重点是确定生产标称合格产品所需的工艺条件，然后进行表征材料和处理性能的测试。这些测试的结果将与滩头增材制造系统供应商发布的验收标准进行比较，以准备纳入3D打印测试组件。该奖项反映了NSF的法定使命，并通过使用基金会的知识价值和更广泛的影响审查标准进行评估，被认为值得支持。

The broader impact/commercial potential of this Small Business Innovation Research (SBIR) Phase I project pertains to the novel production of short-fiber reinforced thermoplastic material applicable to a range of processes, with the added benefit of utilizing high quality, low cost recycled or recovered fibers. The beachhead application is in a powder-based additive manufacturing system capable of mid-scale manufacturing that can bridge between prototype-stage and capital-intensive injection molded economy-of-scale manufacturing. Such systems can be located in regional production hubs to accelerate new or highly-customizable products to market. The inclusion of the proposed additives in these systems will expand the range of end-product material properties available, and thereby expand the potential client pool for the same platform. Anticipated flow properties of the material will position it as an accessible additive option for other 3D printing technologies as well as the much larger-market of injection molding processing.This Small Business Innovation Research (SBIR) Phase I project adapts a processing technology that is yet untapped for this application, to produce a composite thermoplastic additive for polymeric powder feedstock 3D printing. This additive is expected to increase stiffness, strength, and thermal stability of the end product, while reducing weight and providing superior handling characteristics during production relative to existing alternatives. The project is focused on identifying process conditions required to produce a nominally conforming product, followed by testing that characterizes the material and handling properties. Results of these tests will be compared against acceptance standards published by the beachhead additive manufacturing system supplier in preparation for inclusion into 3D printed test components.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.