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.

该小企业创新研究 (SBIR) 第二阶段项目的更广泛影响/商业潜力是使先进的 3D 打印材料能够解决新兴电子设备、运输技术、建筑物加热和冷却系统以及制造过程中热管理方面的挑战。随着电气设备不断变得更加紧凑和能量密集，过热是一个重大挑战。通过传统方法制造的热交换器通常价格昂贵，制造时需要消耗大量能源，并且会遭受腐蚀、性能有限和维护成本高昂。由金属加工的传统模具通常价格昂贵，需要较长的交货时间，并且设计自由度有限。为了应对这些挑战，该项目将开发一种新型高导热复合材料平台，可用于 3D 打印零件，增强电子器件冷却和性能，同时降低产品重量和成本，提高热交换器性能，同时减少腐蚀、结垢和相关维护，还可用于 3D 打印低成本高性能模具，资本成本低，交货时间短。该项目将为工程师提供一个先进的材料平台，以创建具有类金属导热性的零件，同时具有印刷塑料的速度、低成本和最终的设计自由度。这个小型企业创新研究（SBIR）第二阶段项目将开发可 3D 打印的塑料复合材料，导热率比标准塑料高 500 倍。这种独特的材料在 3D 打印长丝中加入了连续的金属丝和纤维，以实现传统制造的复合材料零件不可能达到的导热率值。 聚合物复合材料外壳和线材/纤维芯可定制，以提供高强度、高温稳定性以及均匀的焦耳热。这些材料使用经过修改的硬件和软件平台直接在市售且低成本的独立双挤压 (IDEX) 3D 打印机上打印。打印和长丝生产将通过以下五个目标来实现：1）最终确定所需材料特性的长丝配方，2）建立中试规模长丝生产线以展示生产可扩展性，3）完成对 3D 打印机硬件的细微修改以适应长丝打印，4) 开发软件来打印和优化零件以获得所需的性能，以及 5) 打印应用示例并通过商业相关演示验证产品性能。该奖项反映了 NSF 的法定使命，并通过使用基金会的智力优点和技术进行评估，被认为值得支持。更广泛的影响审查标准。