LEO Manufacturing of 3D Printed Covetic Nanomaterials for Advanced Electronics

This program will develop an in-space material manufacturing approach to leverage the unique capabilities of the International Space Station. Specifically, one such, exemplar novel class of material, covetics (nano-carbon-infused metals), are inherently challenging to produce terrestrially but have great commercial potential due to their enhanced physicochemical properties as compared to conventional metals, such as high thermal (50% higher than Cu), high electrical conductivity (40% higher than 6061 Al), and high strength (30% higher yield strength than Cu). Therefore, Faraday Technology and the University of Texas in Dallas will develop a material manufacturing process to directly print these next generation covetic materials in Low Earth Orbit (LEO) via an electro-codeposition approach. This work will build on the University of Texas#39;s direct Cu printing platform which has been demonstrated at pre-commercial scale the potential to print large area circuit board lines utilizing a localized pulse electrodeposited (L-PED) technique. Additionally, this work will build on Faradayrsquo;s electro-codeposition process activities that include depositing carbon materials into copper. In Phase I we will establish the viability of directly printing covetic materials by developing the direct write hardware and the electro-codeposition electrolytes to deposit electrochemically reduced carbon materials into a copper matrix in an orientation opposite or perpendicular to gravity such that we can demonstrate at the lab scale, the potential to form covetic materials with enhanced electrical, thermal, and mechanical properties. This demonstration would enable a preliminary market need assessment (Phase I) and zero gravity flight demonstration (Phase II), which could establish a commercial market for in-space manufacturing of these exciting covetic materials. If successful the results of the Phase I/II program will set the stage for LEO commercialization of this manufacturing process.