Direct Ink Writing of Functionally Graded Thermoset Materials

The next frontier of additive manufacturing will include technologies that enable operators to leverage thermally cured thermosets for their high thermal and mechanical stability, lightweight features, and low cost. Even with the most advanced 3D printers today, there is a gap in the offerings available that prohibit the use of polyurethanes, epoxies, and silicones that are commonly found in industrial and military-relevant applications. This STTR project proposes to demonstrate the incorporation of Direct Ink Write for 3D printing thermally cured thermosets. In Phase I, several material formulations with the desirable range of properties will be selected for printing. Test specimens will then be made from each formula traditionally by means of casting, and then additively before performing ASTM standard tests to compare and validate material properties. Then, the team will demonstrate the ability to functionally-grade products printed with thermoset materials using JuggerBot 3D’s proprietary software, resulting in the high-quality fabrication of complex structures. Phase II efforts would focus on further developing methodologies to achieve more efficient and stable production with functionally graded thermoset materials at scale. In tandem with process and material development, an emphasis would be placed on the integration of automation to mitigate operator interference and enable the embedding of electronic components. The team will then combine the aforementioned developments with proprietary scanning technology that optimizes processing characteristics for AM. These studies would be used both for calibrating and validating the methods to extend the versatility and robustness of the tools developed.