Additive Manufacturing of Lightweight Multifunctional Structures

Key Technical Challenges: Printing two materials in two different print heads to obtain a robust materials system. \nApproach/Research Plan: Select print materials and design test samples; Conduct initial trials and characterization; Evaluate bi-layer test coupons and optimize; and, Fabricate structural demonstration articles.\nDifferent/Complementary: The lightweight multifunctional structures will be an advancement over conventional designs utilized in industry. They will replace honeycomb structures that are only structural in function. The additive manufacturing of complex parts is also an advancement over conventional approaches which rely on extensive machining and uses adhesives and fasteners to form the components while generating a lot of wastes and requiring multiple parts, fabrication steps, and extensive labor. \nNext Step: A component would be optimally designed, fabricated, and evaluated, with the focus be on light-weight, high strength, integrated functional components. This effort also will help determine the most promising functional aspect such as be thermal, electrical, magnetic, acoustic, or shielding.

Goal: To take advantage of different 3D printing materials with varying temperature capabilities, compositions, and functionalities, in order to fabricate bi-material structures to demonstrate the feasibility for in-space manufacturing and applications. \nCapability Need/Knowledge Gap: A significant gap exists in realizing the full potential of additively manufactured materials in new designs and applications. The filaments, the material properties, the functional characteristics, and the resulting printed structures have not been fully characterized by the technical community and very little information is provided by the suppliers. Print parameters, such as print head temperature, stage temperature, and print layer height need to be investigated. Microstructural analysis, strength testing, and property characterization is needed. \nState-of-the-Art/Knowledge: New lines of commercially available print filaments are being offered which provide higher strength capability, higher temperature capability, and composition modifications/additives for functional properties. Many of the filaments contain secondary phase additions which are typically in the form of powders, particulates, nanotubes, and short fibers. The amount of additions to the base filament materials are not disclosed.

This is early/mid-stage (TRL 2) — 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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