SBIR Phase II: High thermal conductivity continuous fiber reinforced 3D printing materials

SBIR第二期：高导热连续纤维增强3D打印材料

• 批准号: 2129734
• 负责人: Matthew Smith
• 金额: $ 98.25万
• 依托单位: TCPoly
• 依托单位国家: 美国
• 项目类别: Cooperative Agreement
• 财政年份: 2021
• 资助国家: 美国
• 起止时间: 2021-09-15 至 2023-08-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2129734&HistoricalAwards=false
• 关键词: SBIR; Phase; II; thermal; conductivity

The broader impact/commercial potential of this Small Business Innovation Research (SBIR) Phase II project is to enable advanced 3D printing materials to solve challenges in emerging electronic devices, transportation technologies, heating and cooling system for buildings, and in thermal management in manufacturing processes. Overheating is a major challenge as electrical devices continue to grow more compact and energy dense. Heat exchangers manufactured through traditional methods are often expensive and energy intensive to fabricate and suffer from corrosion, limited performance, and high maintenance costs. Traditional mold tools machined from metals are often expensive, require long lead times, and have limited design freedom. To address these challenges, this project will develop a platform of novel high thermal conductivity composite materials that can be used to 3D print parts that enhance electronics cooling and performance while also reducing the product weight and cost, can improve heat exchanger performance while also reducing corrosion, fouling and associated maintenance, and can also be used to 3D print low cost and high-performance molds with low-cost capital and short lead times. The project will result in an advanced materials platform for engineers to create parts with metal-like thermal conductivity, but with the speed, low cost, and ultimate design freedom of printing plastics.This Small Business Innovation Research (SBIR) Phase II project will develops 3D printable, plastic composite materials with 500x higher thermal conductivity than standard plastics. The unique materials incorporate continuous wires and fibers in 3D printing filaments to achieve thermal conductivity values not possible in traditionally manufactured composite parts. The polymer composite shell and wire/fiber core can be tailored to offer high strength, high temperature stability, and even joule heating. These materials are printed directly on commercially available and low-cost Independent Dual Extrusion (IDEX) 3D printers using a modified hardware and software platform. Printing and filament production will be accomplished through the following five objectives: 1) finalize filament formulations for the desired material properties, 2) establish a pilot scale filament manufacturing line to demonstrate production scalability, 3) complete minor 3D printer hardware modifications to accommodate filament printing, 4) develop software to print and optimize parts for desired properties, and 5) print application examples and validate product performance with commercially relevant demonstrations.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.

这项小型企业创新研究（SBIR）II期项目的更广泛的影响/商业潜力是使高级3D打印材料能够解决新兴的电子设备，运输技术，供暖和建筑物的冷却系统以及制造过程中的热管理挑战。过热是一个重大挑战，因为电气设备继续增长更紧凑和能量致密。通过传统方法制造的热交换器通常是昂贵且能量密集的，以制造和遭受腐蚀，性能有限和高维护成本。从金属加工的传统模具工具通常很昂贵，需要长时间的交货时间，并且设计自由度有限。为了应对这些挑战，该项目将开发出一种新型高温电导率复合材料的平台，该平台可用于3D打印零件，以增强电子设备冷却和性能，同时还可以降低产品的重量和成本，可以提高热交换器的性能，同时还可以减少腐蚀，结垢和相关的维护，并且还可以将3D打印的低成本和高成本和高度的领先优势置于低点量和零件量。该项目将为工程师提供一个高级材料平台，以创建具有金属样导热率的零件，但是速度，低成本和最终设计的印刷塑料自由。这项小型企业创新研究（SBIR）II期项目将开发3D可打印的，可打印的塑料复合材料，其热导率比标准塑料高500倍。独特的材料在3D打印丝中融合了连续的电线和纤维，以实现传统制造的复合零件中无法实现导热率值。 可以对聚合物复合壳和电线/纤维芯进行量身定制，以提供高强度，高温稳定性甚至加热。这些材料直接印刷在使用修改的硬件和软件平台的市售和低成本独立双重挤出（IDEX）3D打印机上。打印和细丝生产将通过以下五个目标来完成：1）最终确定所需材料特性的灯丝配方，2）建立一条试验量表制造线以证明生产可伸缩性，3）完整的次要3D打印机硬件修改，以适应灯丝印刷，4）开发和优化所需的副本的零件，以及5）定型产品的绩效，5）定型产品效果，5）定型产品的效果。 NSF的法定使命，并使用基金会的知识分子优点和更广泛的影响审查标准来评估值得支持。