Development of Additive Manufacturing for Neutron Scattering Collimators

Additive manufacturing (AM) technology (aka “3D printing”), through its unique layer-by-layer, freeform fabrication capability, has the potential to revolutionize the way neutron collimators (and other neutron conditioning optics (NCOs)) are designed and built, enabling enhanced performance at lower cost. However, there is a need to develop and optimize feedstock materials, along with AM processing parameters, incorporating neutron absorbing elements. In this proposal, RadiaBeam Systems, LLC will develop in-house facilities to process and manufacture novel neutron absorbing material (NAM)-loaded filaments for use in commercial FFF/FDM® 3D-printing systems. A prototype NCO component will be fabricated and tested in a neutron beamline. In Phase I, we have successfully developed custom FFF compatible NAM-loaded filaments incorporating up to 50% Boron Carbide (B4C) by mass and fabricated and characterized sample geometries using our in- house commercial fuse filament fabrication (FFF) 3D-printing systems. In Phase II we will develop and optimize new NAM-loaded filament composition(s) and FFF processing parameters, design and fabricate a prototype NCO, and validate its performance in a neutron environment. This work will result in the development and commercialization of new FFF/FDM® compatible feedstock filaments incorporating neutron absorbing elements for use in 3D-printed neutron collimators and other NCOs. The techniques and products being developed here have broad commercial applications for neutron scattering facilities, as well as commercial and Defense radiation shielding. Additional applications include shielding components for scientific instrumentation used in high radiation environments such as high energy particle accelerators.