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It is proposed to overcome current deficiencies in ISAM by developing thermal-curing thermosets with embedded fibers, and to move this new technology toward commercial feasibility. The work involves exploring benefits of low-gravity for innovative control of liquid spreading during extrusion, and quantifying the proper conditions for embedding composite fibers in the thermosets. The proposed effort includes these technical tasks: (i) Develop analytical simulations of the proposed ISAM methodology. (ii) Extrude droplets, puddles, and linear beads of thermal-curing thermosets on heated surfaces, and compare to simulations. (iii) Use calibrated models to predict performance in varied-gravity environments. (iv) Embed composite fibers into extruded thermosets using a modified 3D printer.
In the future, this work in design and predictive modeling will be useful for AM and deposition of new materials beyond thermal-curing thermosets with embedded fibers, such as recycled feedstock, concrete, high-temperature thermoplastics, and even regolith.
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