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Completed TRL 3 (started at 2, targeting 4)
The recent discovery by the Aerogel Team at NASA's Glenn Research Center of sol-gel derived thermally reversible polymer gels has uncovered the possibility of creating a lightweight complex hierarchical aerogel structure via disruptive manufacturing technologies which have not been seen to date. This project will explore techniques to create complex 3-dimensional, structurally sound polymer aerogel architectures using 3-d printing, rapid gel prototyping, or other types of solid freeform (SFF) and additive manufacturing (AM) for use in a myriad of aero and space applications. State of the art materials for thermal management, chemical detection, air filtration, acoustic impedance or vibration dampening traditionally use bulky or layered composites. The ability to rapidly assemble 3-dimensional complex polyimide aerogel architectures using the polyimide gel would decrease or eliminate existing issues with these technologies such as weak fracture joints, spalling, and delamination. Current research by Lawrence Livermore National Laboratory has used direct ink printing to produce carbon aerogel structures via incorporation of a stabilizing inorganic filler. The use of sol-gel derived polyamide thermally reversible gels requires no thickening agents or fillers for production of the polymer aerogel and can be chemically manipulated to exhibit desirable characteristics such as hydrophobicity, optical clarity, and enhanced thermal resistance. Additive manufacturing equipment at GRC can be used to accomplish the objective of producing 3D complex structures using a polyimide gel medium while taking advantage of in house synthesis knowledge to develop cross-linking methods to improve properties. The goal of this research and development effort is to focus on demonstrating the feasibility of producing complex structures of cross-linked polyimide aerogels through various gel based printing techniques.
The technology has near term benefits in the ability to produce a material that is in high commercial demand without the use of a mold. The far term benefits include production of lightweight support structures, complex antennas, energy storage/power devices, and acoustic barriers for Vertical Take-off and Landing (VTOL) vehicles. These benefits align with Mission Responsive R&D in Core Competency areas of Materials and Structures for Extreme Environments (Lightweight Concepts), and is a Crosscutting Technology for both ARMD and STMD. The ability to manufacture polyimide aerogels with this technology would allow for various complex geometries and architectures unattainable through molding processes. The unique spatial and temporal material manipulation capability will open the door for novel multifunctional systems which can be directly incorporated into VTOL's with the combined benefits of enhanced thermal management, acoustic impedance, and air filtration. A material with these characteristics would satisfy the imminent Agency and National need for noise mitigation and public safety concerns surrounding the Urban Airlift Vehicles.
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