Low Cost, Multi-Materials, Additive manufacturing Process for Space System Applications (1000-356)

ABSTRACT: SI2 Technologies, Inc. (SI2) will develop a unique multi-material additive manufacturing solution for multi-functional space components.By leveraging experience and capabilities in Direct Write deposition with electromagnetic/RF and structural design expertise, SI2 will design andadditively manufacture an embedded x-band array that will meet current and future Air Force needs, such as reducing cost and weight, on space systems.The multi-material deposition process will produce complex prototype and low volume production components.Coupon level testing will verify that the materials and processes utilized will produce parts that will withstand the harsh space environment.In Phase I, SI2 will verify that the base materials will survive the relevant environment and develop the multi-materials additive manufacturing process to build space system components.The multi-materials additive manufacturing process developed will be validated through the design, manufacture and characterization of the demonstrator to verify it meets the defined performance requirements.The results of the Phase I effort will be used to develop a technology transition plan to guide the future development of the technology starting in Phase II, where the process will be optimized and scaled for use on other parts and part types, and lasting through transition to a Program of Record.; BENEFIT: SI2 will define, develop and refine the additive manufacturing materials and processes needed to demonstrate the feasibility of the proposed solution for use in space system applications. Baseline material properties will be measured and used to support the part design process.SI2 will then validate the process to a TRL/MRL 3 level by designing, manufacturing and verifying the performance of a demonstration article, such as an embedded x-band array.Work in Phase II will concentrate on refining and optimizing the additive manufacturing materials and processes.Additional baseline material testing will augment the database developed in the Phase I effort and include new materials and more comprehensive material characterization.SI2 will work to identify other parts and part types that could be manufactured via the SI2 developed multi-materials additive manufacturing process.A demonstrator part will be downselected and multiple copies of the part manufactured and characterized to show the accuracy and precision of the manufacturing process.Characterization in the Phase II will include functional and environmental testing.It is anticipated that the Phase II project will result in a TRL 6/7 for the process and manufactured component. Other DoD high volume applications include low cost x-band SATCOM for Army BFT-3. Commercial applications include low cost x-band antenna and arrays weather monitoring, air traffic control, maritime vessel traffic control, and vehicle speed detection for law enforcement.