Novel Sensor Solutions for Qualification of Additively Manufactured Launch and Space Vehicle Components

This Phase I SBIR will demonstrate that IDS’s NanoJet (NJ) Aerosol Printing solution can be used to print embedded sensors into 3D printed structures on a layer-wise basis. These sensors can be used for qualification of Additive Manufacturing (AM) components during printing and subsequently for other functions during the lifetime of AM components. The NJ technology is a unique print technology with a print nozzle standoff distance from the print surface of 2-6mm. This standoff distance is advantageous over other printing technologies and enabling for the NJ technology for printing over nonplanar surfaces or into cavities. The NJ technology has several other unique attributes making it ideal for printing embedded features layer-by-layer in conjunction with structural 3D printing processes. Recent results show that printed conductive Ag traces are cured in-situ during printing. A second print cartridge included in the two-material NJ print head allows printing of dielectrics above and beneath cured NJ printed conductors fully encapsulating conductors. UV curing dielectric material makes it possible to immediately 3D print over the NJ printed features to embed those printed features within the 3D printed structure. Printing conductors and dielectrics from the same nozzles maintains alignment between printed features.