Novel Non-Melt Additive Manufacturing Powder (NNAMP)

MPW has developed a non-melt technology to produce powders from bar stock has already been demonstrated in pilot powder making, powder characterization, additive manufacturing (AM – both Laser Powder Bed Fusion and Cold Spray) trials, and mechanical and micrographic testing of aluminum and copper alloys.  The ability to obtain a very high (>95%) yields in any desired powder size distribution (PSD - 15µm-45µm, 45µm-105µm, etc.) and the machine productivity has also been determined for these alloy systems.  Early-stage trials have also demonstrated the making powder from polymers, hard alloys, and ceramics is also possible.  In this proposed SBIR Phase I program, MPW will address the feasibility of our process and machine to meet the widest possible range of Navy needs.  This starts with gaining a prioritized understanding of what the Navy wants in terms of alloys/materials, PSD, machine and powder cost, downstream processes, portability, ease of use, etc.  Using this, MPW will modify one of its current machines to better address a broader range of alloys.  It will then produce significant quantities of the prioritized powders and demonstrate their suitability via standard powder characterizations and trials in one or more AM processes, and economics, as well as providing quantities of powder to the Navy for its evaluation.