Repeatable and Scalable Innovative Production Methods for DLA Critical Supply Chain Products

NanoSonic is a small, advanced materials company with expertise in the development of new materials using additive manufacturing (AM) processes for performance enhancements and cost reduction.  Through related work with the DLA, NanoSonic has become an approved source for Industrial Rubber Gloves (NSN(s): 84150082374(58,59,60) using seamless dipping, and is using advanced extrusion techniques for the repeatable production of reliable inflatable seals (NSNs: 5330-01-651-7784) and jet engine blankets (NSN: 1560-00-799-0604).  Important to duplicability for each of these parts is robotics-based automation which removes guesswork from hands-on touch labor.  As such, each of these products shall benefit from metal and high temperature 3D printed molds to reduce risk and increase acceptance rates potentially to 100%.  This method shall repeatably produce critical parts such as inflatable canopy seals and related durable critical parts such as nacelle blankets for current aircraft and legacy programs of record.  During this Sequential Phase II DLA SBIR program, molds shall be developed for NanoSonic’s extruded seals and Thermal Array insulation using metal binder jet printing methods and custom high temperature fused filament fabrication systems in NanoSonic’s dedicated 3D print laboratory