I-Corps: Expanding Additive Manufacturing Utilization through Post Processing for Improved Mechanical Properties

这个i-Corps项目的更广泛的影响/商业潜力是开发一种后处理方法来显著改善性能，包括灵活的几何形状和廉价的小批量生产。加法制造为制造复杂几何形状和降低小批量生产成本提供了革命性的机会。然而，AM聚合物零件的低韧性/延展性限制了冲击。该项目预计将大大扩大现有AM聚合物制造基地的影响。低容量AM的几何灵活性将使新的定制产品成为可能。这可以带来新的机会，例如增加对个别患者的医疗设备部件的定制。它在降低停产设备的维护成本和减少偏远地区的供应链挑战方面也将特别有价值。这个i-Corps项目基于开发一种方法，对现有商业流程中的部件进行后处理，以实现显著的财产改进。后处理聚合物粉末床熔合组件提高了延展性、各向同性和韧性。该技术适用于所有商业产品或聚合物粉末床熔融，有望应用于广泛的聚合物材料。该系统已在实验室中演示，实现了显著的性能改进。该项目将确定这一功能的潜在客户，并量化它将为客户增加的价值。此外，该项目将探索可用于将技术商业化的不同商业模式，以评估将这种能力从实验室转化为生产的最可行的商业化路径。该奖项反映了NSF的法定使命，并通过使用基金会的智力优势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 I-Corps project is the development of a post-processing method to dramatically improve properties, including a flexible geometry and inexpensive low-volume production. Additive manufacturing opens revolutionary opportunities for fabricating complex geometries and lowering the cost of low-volume production. However, the impact has been restrained by the low toughness/ductility of AM polymer parts. This project is expected to substantially expand the impact of the existing AM manufacturing base for polymers. The geometric flexibility of low volume AM will enable new customized products. This can allow new opportunities such as increased customization of medical device components to individual patients. It will also be especially value in lowering the costs of maintaining out-of-production equipment and reduce supply chain challenges in distant locations.This I-Corps project is based on the development of a method to post-process parts from existing commercial processes to achieve dramatic property enhancements. The post-processing polymer powder bed fusion components increase ductility, isotropy, and toughness. The technology is applicable to all commercial products or polymer powder bed fusion and is expected to apply to a wide range of polymer materials. The system has been demonstrated in the lab to achieve significant property improvements. This project would identify the potential customers for this capability and quantify the value that it would add for customers. Additionally, the project will explore the different business models available for commercializing the technology to assess the most feasible commercialization paths for transitioning this ability from the lab to production.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.