Scalable, Non-Traditional Additive Manufacturing printing of inexpensive metallic structures

Award Information
Agency: Department of Defense
Branch: Army
Contract: W56HZV-19-C-0005
Agency Tracking Number: A181-104-0106
Amount: $99,999.37
Phase: Phase I
Program: SBIR
Solicitation Topic Code: A18-104
Solicitation Number: 2018.1
Timeline
Solicitation Year: 2018
Award Year: 2019
Award Start Date (Proposal Award Date): 2018-11-14
Award End Date (Contract End Date): 2019-05-13
Small Business Information
11008 Chelsea Way, Laurel, MD, 20723
DUNS: 080528211
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Yongzhang Leng
 (301) 793-8588
 yleng@3dflexible.com
Business Contact
 Victor Yun
Phone: (301) 256-5282
Email: vyun@3dflexible.com
Research Institution
N/A
Abstract
Metal Additive Manufacturing (AM) is the ultimate prize in 3D printing technology because this technology could spread beyond the prototyping and customized production phases and revolutionize manufacturing, supply chains and logistics. However, the ARMY states that no current AM processes meet its needs to print large metallic structures. To meet the Armys urgent need, we propose to develop and validate a new class of AM process to overcome limitations of current technologies. Contrary to metal powder bed technology, we have succeeded in preparing viscoelastic metallic pastes and printed simple metal structures with high aspect ratios. Numerous silver and copper pastes exist for AM electrical traces, but suitable metallic pastes for structural applications are not commercially available.Using our approach, metallic structures with complex features (cavities and voids) can be fabricated through further metallic paste development and CAD/CAM toolpath optimization. Our process doesnt require energy beam heating, binders, or processing chamber/shielding gases. This technology is easily scalable. Our metallic structures were sintered below 2500C. Additional research is essential to develop our metallic paste process to cover ferrous, Cobalt, Nickel-based alloys, and to develop the relevant AM processes to meet the Armys needs and to achieve widespread adoption within Armys organic base.

* Information listed above is at the time of submission. *

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