Magnetic Powders and Heterogeneous Gradient Additive Manufacturing Techniques

A breakthrough, scalable, high-volume process for manufacturing known-quality low-loss, high-index, and high-wave characteristic impedance magnetic powders with particular electromagnetic characteristics and additive manufacturing (AM) processes will be developed, which allow for fabrication of functional materials with 3D-graded electromagnetic properties. The materials and processes will be optimized for use in manufacturing advanced radomes, with enhanced performance and protection of antennas from weather elements. Using magnetic ceramics and magneto-dielectric polymer nanocomposite inks, fabricated using scalable processes, and deposited using inkjet print and powder-bed fusion AM fabrication, a series of homogeneous and heterogeneous samples will be fabricated, and their physical and magneto-dielectric properties measured. Then it will be shown how 3D freeform magneto-dielectric structures can be fabricated, using scalable AM processes and hardware. These structures will include multiple materials, including metals, plastics, and composites. The demonstration and characterization of the materials and processes will reduce the risk of the Phase II program, wherein the readiness level of the technology will be increased, and functional parts will be fabricated and qualified.