Post-Processing-Free 3D Printing for Low Mass, Multifunctional Polymer Composites

The central objective of the proposed work is to develop low mass, multifunctional materials by tailoring their production from the molecular to the macroscopic level. The hypothesis is that combining DIW with known chemistries and curing techniques will produce lightweight, porous polymer nanocomposites requiring no post-processing, with tunable properties (e.g., pore size, flexibility, and modulus) and functionalities.

One low-mass, multifunctional process for producing these materials is direct ink writing (DIW) 3D printing (3DP), which is inexpensive, robust, requires minimal infrastructure, and can produce objects with complex geometries on demand. DIW prints thixotropic inks that solidify quickly after extrusion at room temperature. For these reasons, DIW is optimal for 3DP in the extreme environment of space. However, DIW of lightweight, multifunctional materials is currently limited by material selection and harsh post-processing steps. In order to make 3DP accessible in space, these post-processing requirements must be addressed to produce low-mass, multifunctional materials as easily as possible.

Through the proposed work, I will: 1) significantly simplify the post-processing of 3DP porous structures, and 2) expand the range of microstructures and material properties which can be accessed by 3DP. In order to print porous materials, I will use Pickering emulsions to combine reactants at the point of extrusion from a DIW printer, so that the shear force at the extrusion point disrupts the emulsion stability to form a solid. Because this reaction is controlled, air can be incorporated into the 3DP process to produce pores in the solid. Additional curing of the printed object via water or ultraviolet (UV) light expands the mechanical properties achievable by these materials. I will optimize the resulting low mass, multifunctional composites to meet specific NASA needs. This work will transform the capabilities of additive manufacturing, enabling real-time production of lightweight, multifunctional composites across length scales in a variety of environments while requiring minimal infrastructure to prove particularly applicable in space.

This work will transform the capabilities of additive manufacturing, enabling real-time production of lightweight, multifunctional composites across length scales in a variety of environments while requiring minimal infrastructure to prove particularly applicable in space.

This is early/mid-stage (TRL 3) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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