Additive Manufacturing of Ultra-low Density Buoyancy Foam

Microsphere Material Solutions, LLC (MMS) of Rockville, MD - developer and manufacturer of high-strength, low-weight glass foams for buoyancy, armoring and safety applications - offers an innovative low-density closed-cell glass foam for submersible applications. In the second phase of the SBIR, MMS will increase the strength of its amorphous glass foam offerings by fabricating hollow E-glass spheres with 3-5 times the strength of today’s commercial offerings. MMS will start by fabricating aluminum foam which is also within the specifications desired by the Navy while being less challenging to develop. The unparalleled strength of the feedstock will enable a new generation of buoyancy materials with unprecedented strength. MMS will then develop an additive manufacturing (AM) system based on droplet deposition to reduce material waste by up to 50%. By the end of Phase II, MMS will possess an automated platform for printing foam structures = 30cm?30cm?5cm from user-inputted geometries with costs below 0.05 $/cm3. The proposed foams will enable submersible vehicles to operate at higher speeds and/or with larger payloads, reducing the level of exposure and stress for personnel in manned submersibles and increasing effectiveness of unmanned undersea vehicles. E-glass spheres alone will generate initial sales revenue of ~$20-50k/month.