Binder Jet based Additive Manufacturing of Ni-Zn Ferrite Composites Enabling High Power Microwave (HPM) Directed Energy Weapons (DEW)

Hepburn and Sons LLC teamed with the University of Pittsburgh proposes a binder jet 3D printing (BJ3DP) additive manufacturing process with Ni-Zn Ferrite Composites and BaTiO3 batch infiltration to produce ferromagnetic and ferroelectric composite components that are power dense, cost-effective, high-resolution, and high-performance to enable High Power Microwave (HPM) Directed Energy Weapons (DEW) for Navy use. HPM generator technology has received increased attention corresponding with the emergence of non-lethal DEW as well as with improved wireless radar technologies. Priority is placed on minimizing size, weight, power, and cost (SWAP-C) for HPM sub-systems and optimizing its energy density at electronic targets of different sizes. HPM systems will benefit from BJ3DP capabilities as alternative to conventional, more costly fabrication and prototyping, sintering, and machining.