Ultrasonic Additive Manufacturing for Efficient Space Vehicles

The goal of this Phase II SBIR program is to demonstrate the application of Ultrasonic Additive Manufacturing (UAM) solid state metal 3D printing to create new and innovative of metal matrix composites for selective reinforcement and lightweighting. Our intent is to enable Space Launch System structures with superior mechanical properties and increased reliability, and validate these advancements with third party testing. Specifically, this effort will develop lightweight and multifunctional composite components in aerospace aluminum alloys, selectively reinforced with metal matrix composite, and study the effect of embedding on structural integrity using UAM-embedded mechanical strain gauges. With NASA guidance, the project team Phase II plan is to select and develop functional prototypes of Space Launch System structures to illustrate efficient space vehicle concepts. A demonstration unit will be delivered to NASA for testing at the completion of the Phase II contract.