Printed Hybrid Electronics (PHE) in a Flight Environment: 3D Printed Electronics on Suborbital Technology Experiment Carrier 9 (SubTEC-9)
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Additive Manufacturing↗
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Results for “3D PRINTING”
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Effect of printing parameters on the sensing performance of a 3D printed elastomeric pressure sensor
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Nicholas Babich↗
Vibration induced active rheology control for 3D concrete printing
3D concrete printing, an emerging automation technology for construction, requires the concrete to be flowable during pumping and extrusion but firm immediately after layer deposition. This study investigated an active rheology control using vibration to achieve these opposing requirements. The effects of vibration frequency and acceleration on rheological parameters of concrete were studied with different levels of nanoparticles in the mix. It was found that extrusion pressure and yield stress show less sensitivity to the peak velocity of the vibration up to a certain level and then they both decrease beyond this level. Also, certain level of nanoparticles inclusion found to double the reduction in extrusion pressure and yield stress. Buildability studies using 3D printers were conducted to demonstrate the active rheology control using vibration. The mechanical properties of the printed structures were also found to have improved when vibration rheology control was used.
36 MATERIALS SCIENCE↗
Operando neutron diffraction reveals mechanisms for controlled strain evolution in 3D printing
Abstract Residual stresses affect the performance and reliability of most manufactured goods and are prevalent in casting, welding, and additive manufacturing (AM, 3D printing). Residual stresses are associated with plastic strain gradients accrued due to transient thermal stress. Complex thermal conditions in AM produce similarly complex residual stress patterns. However, measuring real-time effects of processing on stress evolution is not possible with conventional techniques. Here we use operando neutron diffraction to characterize transient phase transformations and lattice strain evolution during AM of a low-temperature transformation steel. Combining diffraction, infrared and simulation data reveals that elastic and plastic strain distributions are controlled by motion of the face-centered cubic and body-centered cubic phase boundary. Our results provide a new pathway to design residual stress states and property distributions within additively manufactured components. These findings will enable control of residual stress distributions for advantages such as improved fatigue life or resistance to stress-corrosion cracking.
36 MATERIALS SCIENCE↗
The role of cellular structure, non-equilibrium eutectic phases and precipitates on quasi-static strengthening mechanisms of as-built AlSi10Mg parts 3D printed via laser powder bed fusion
The quasi-static loading strengthening mechanism in the as-built state of an AlSi10Mg alloy 3D-printed via Laser Powder Bed Fusion (LPBF) was thoroughly identified and quantified using state-of-the-art electron microscopy and synchrotron X-ray diffraction techniques. The yield strength was comprehensively modelled through an in-depth characterization and quantification of the microstructural features as well as their effective volumes for strengthening. In particular, the non-equilibrium eutectic network was characterized with a two-fold structure: cell boundary particles as well as intracellular lamellar/fibrous networks, each consisting of discrete phases exhibiting a thru-thickness compositional gradient, a semi-coherent interface with the matrix and an abundance of crystal defects such as nano-sized sub-grains, microstrains and stacking faults. Further, these altogether made the eutectic phase the most potent contributor to the yield strength accounting for ~30–40% of the estimated value (i.e., cell boundary and eutectic network strengthening combined). Precipitates strengthening was identified as the second most potent mechanism via a shearing process only. Moreover, the presented methodology was able to capture the effect of LPBF processing variables on the individual strengthening contributions, e.g., the effect of a lower laser scanning speed on increasing the cell size as well as the mean precipitate size, which are shown to exhibit opposing impacts on strengthening.
36 MATERIALS SCIENCE↗
3D Printing of Polyelectrolyte Complex-Integrated Photocurable Hydrogel Resins
In this study, we developed a photocurable hydrogel resin incorporating a polyelectrolyte complex (PEC) for 3D printing. Acrylamide-based monomers were formulated with varying PEC contents (0–15 wt %) in an aqueous KBr medium to fabricate patterned porous hydrogel structures. The morphology of printed hydrogels was characterized by field-emission scanning electron microscopy and energy-dispersive X-ray spectroscopy. Notably, the PEC5 and PEC10 formulations exhibited optimal thermal stability and compressive properties, attributed to the homogeneous distribution of PEC domains within the hydrogel matrix. Furthermore, dye adsorption experiments demonstrated excellent removal efficiency, highlighting the potential of PEC-containing hydrogels for environmental remediation applications, particularly in the treatment of dye-contaminated wastewater.
Yang, Jinchul [University of Tennesse Knoxville]↗
NASA SIBatt-3D: In-Space and On-Surface 3D Printing Sodium-Ion Batteries from ISRU Materials
Sustainable on-demand power solutions are an absolute necessity as humanity works to establish a permanent presence on the moon and make the journey to Mars. NASA’s SIBatt-3D project is developing shape-conformable Sodium-Ion batteries that can be 3D printed in-space as needed during extended space missions. SIBatt-3D seeks to utilize materials found in Lunar/Martian regolith as feedstocks to provide sustainable power for surface operations. SIBatt-3D’s batteries also have terrestrial implications such as improved battery safety and sustainability.
Cameroun Sherrard↗
Mass spectrometric investigations into 3D printed parts to assess radiopurity as ultralow background materials for rare event physics detectors
The mass concentrations of 232 Th and 238 U in several 3D printing filaments and printed polymer parts are reported as measures of their radiopurity. In order to minimize background signals in rare event physics detectors, radiopure polymers are necessary as dielectric and structural materials in their construction. New data are reported for polyvinylidene fluoride (PVDF), polyphenylene sulfide (PPS), and two forms of polyetherimide (PEI, branded ULTEM 1010 and 9085). Data for starting filaments and both simple and complex printed parts are reported. PVDF filaments and simple printed beads, were found to have values of approximately 30 and 50 pg g -1 for 232 Th and 238 U, respectively, while a more complex spring clip part had slightly elevated 232 Th levels of 65 pg g -1 , with 238 U remaining at 50 pg g -1 . PPS filament was found to have concentrations of 270 and 710 pg g -1 for 232 Th and 238 U, respectively, and were not chosen to be printed as those levels were already higher than other material options. ULTEM 1010 filaments and printed complex spring clip parts were found to have concentrations of around 5 and 7 pg g -1 for 232 Th and 238 U, respectively, illustrating no significant contamination from the printing process. ULTEM 9085 filaments were found to have concentrations of around 9 and 5 pg g -1 for 232 Th and 238 U, respectively, while the printed complex spring clip part was found to have slightly elevated concentrations of 25 and 7 pg g -1 for 232 Th and 238 U, respectively. All these results were obtained using a novel dry ashing method in crucibles constructed of ultralow background electroformed copper or, when applicable, microwave assisted wet ashing digestion. Samples and process blanks were spiked with 229 Th and 233 U as internal standards prior to dry/wet ashing and determinations were made by inductively coupled plasma mass spectrometry (ICP-MS). In order to maintain high radiopurity levels, pre-cleaning the filaments before printing and post-cleaning the parts is recommended, although the printing process itself has shown to contribute very minute amounts of radiocontaminants.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
Metallization of 3D Printed Parts for Electrode Fabrication
Additive manufacturing has the potential to fabricate electrodes with extremely small features with control of the electrode structure. However, most of the 3D printing capabilities produce structures made of polymers rather than electrodes which much be metal. This work aims to compare methods of metallization for parts created with additive manufacturing to allow them to be used as electrodes. We used three different methods of metallization: layer-by-layer gold nanoparticle coating, electroless copper deposition, and a combination of the two. We measured the resistance of the samples and observed the uniformity of the coating. We find that the standard electroless deposition procedure and using the layer-by-layer gold as a pretreatment yield similar resistances of less than 1 Ω. However, using gold as a pretreatment has possible cost benefits as compared to the standard electroless deposition procedure. Therefore, if many samples over a long period of time need to be metallized, we recommend using the layer-by-layer process combined with copper electroless deposition.
36 MATERIALS SCIENCE↗
Fission gas retention of densely packed uranium carbonitride tristructural-isotropic fuel particles in a 3D printed SiC matrix
The Transformational Challenge Reactor (TCR) fuel form was designed to contain large, densely packed uranium carbonitride (UCN) tristructural-isotropic (TRISO) fuel particles within a 3D printed SiC matrix, increasing the uranium density compared to conventional TRISO fuel forms and offering full geometric freedom for core design. Here, this work summarizes initial low-burnup, high-power irradiation testing of TCR fuel materials, including loose UCN TRISO particles and integral fuel compacts with ~55% TRISO particles by volume, to evaluate fission gas retention. Fission gasses were fully retained in all loose particle tests and in integral compacts irradiated at low (<250 °C) surface temperatures. Initial testing at higher (~700–750 °C) fuel surface temperatures showed fission gas release (FGR) and complete fracture of three compacts, but no FGR was observed in later high temperature tests (~300–750 °C) of both fueled compacts and loose TRISO particles. Calculated thermal stresses in the failed compacts were far less than the measured strength of the SiC matrix and the stresses in some failed compacts were less than those in compacts that did not show FGR. Thermal stress-induced matrix cracks also would not cause complete fracture because the tensile stresses transition to compression in the higher temperature regions. Therefore, fuel failure was likely not caused by thermal stresses and may have been related to leakage currents from the electrical heaters and erratic fuel surface temperatures that were only observed in the test for which failure was observed. In any case, the matrix cracks propagated through the coatings of TRISO particles located in the high-density matrix regions on the peripheries of the compacts, resulting in measurable fission gas release. The discussion focuses on the importance of understanding matrix density distributions and the particle-matrix interface properties to prevent matrix cracks from causing TRISO particle failures.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Tuning the thermal response of 3D-printed bilayer hydrogels via architectural control using binary ethanol–water solvent systems
While stimuli-responsive materials can be prepared via many established procedures, digital light processing (DLP) 3D printing offers a simple and robust technique for the fabrication of hydrogels, including spatially-defined bilayer systems.
Klincewicz, Francis↗
3D printed porous silicone polymer composites using table salt as a sacrificial template
The incorporation of different functional fillers into the DIW composite resin can expand the functionality of 3D printed porous materials for different applications.
36 MATERIALS SCIENCE↗
3D-Printed mmWave Quasi-Holographic Antenna for 2-D Beamforming
This paper presents the design and manufacturing of a novel 2D-scanning antenna that integrates a 3D-printed Rotman lens with a quasi-holographic leaky-wave antenna (HLWA). The proposed design achieved beam-scanning capabilities by leveraging the beamforming of the Rotman lens and the high-gain directive properties of the quasi-HLWA. The Rotman lens (RL) enables beam steering in the elevation plane by switching between input ports. The quasi-HLWA, designed using holographic principles, achieves frequency-controlled beam scanning in the azimuth plane. The entire antenna structure was fabricated using additive manufacturing with an Ink1092 substrate and silver ink for the conductive traces. This approach provides greater control over material placement and design freedom compared to traditional methods. A 25° transmission linear substrate taper was used to ensure good impedance matching between the Rotman lens and the quasi-HLWA, allowing greater gain while maintaining a good scanning range. The experimental results validate the 2D scanning capability of the proposed antenna. The antenna system provides coverage from −54° to 54° in the elevation θ plane and −28° to 28° in the azimuth plane ϕ , with a maximum measured gain of 21.3 dBi at 28 GHz with an average radiation efficiency η=60 %. The fabricated prototype was tested, and the performance was in good agreement with the simulated performance.
Rotman lens↗
3D Printing of Aqueous Two-Phase Systems with Linear and Bottlebrush Polyelectrolytes
In this study, we formed core–shell-like polyelectrolyte complexes (PECs) from an anionic bottlebrush polymer with poly (acrylic acid) side chains with a cationic linear poly (allylamine hydrochloride). By varying the pH, the number of side chains of the polyanionic BB polymers (Nbb), the charge density of the polyelectrolytes, and the salt concentration, the phase separation behavior and salt resistance of the complexes could be tuned by the conformation of the BBs. By combining the linear/bottlebrush polyelectrolyte complexation with all-liquid 3D printing, flow-through tubular constructs were produced that showed selective transport across the PEC membrane comprising the walls of the tubules. These tubular constructs afford a new platform for flow-through delivery systems.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Effect of Fe on Co-Based SiO2Al2O3 Mixed Support Catalyst for Fischer–Tropsch Synthesis in 3D-Printed SS Microchannel Microreactor
This research explores the effect of a composite support of SiO2 and Al2O3 with Fe and Co incorporated as catalysts for Fischer–Tropsch synthesis (FTS) using a 3D-printed stainless steel (SS) microchannel microreactor. Two mesoporous catalysts, FeCo/SiO2Al2O3 and Co/SiO2Al2O3, were synthesized via a one-pot (OP) method and extensively characterized using N2 physisorption, XRD, SEM, TEM, H2-TPR, TGA-DSC, FTIR, and XPS. H2-TPR results revealed that the synthesis method significantly affected the reducibility of metal oxides, thereby influencing the formation of active FTS sites. SEM-EDS and TEM further revealed a well-defined hexagonal matrix with a porous surface morphology and uniform metal ion distribution. FTS reactions, carried out in the 200–350 °C temperature range at 20 bar with a H2/CO molar ratio of 2:1, exhibited the highest activity for FeCo/SiO2Al2O3, with up to 80% CO conversion. Long-term stability was evaluated by monitoring the catalyst performance for 30 h on stream at 320 °C under identical reaction conditions. The catalyst was initially active for the methanation reaction for up to 15 h, after which the selectivity for CH4 declined. Correspondingly, the C4+ selectivity increased after 15 h of time-on-stream, indicating a shift in the product distribution toward longer-chain hydrocarbons. This trend suggests that the catalyst undergoes gradual activation or restructuring under reaction conditions, which enhances chain growth over time. The increase in C4+ products may be attributed to the stabilization of the active sites and suppression of methane or light hydrocarbon formation.
Biochemistry & Molecular Biology↗
In-Situ Resource Utilization: Robotics and 3D Printing as the Picks and Shovels of the 21st Century
Presentation is in support of NASA Kennedy Space Center (KSC) Speaker's Bureau Event (request #19-125546), which is about robotics and 3D printing as the new tools (vs. picks and shovels) for the lunar surface.
Nunez, Jose↗
3D-printed ketoenamine crosslinked polyrotaxane hydrogels and their mechanochromic responsiveness
A ketoenamine-based dynamic covalent crosslinker was introduced here to α-cyclodextrin-based polypseudorotaxanes, forming viscoelastic hydrogels for direct-ink-write 3D printing. The irreversible enol–keto tautomerization imparts high chemical stability to the extensively crosslinked polyrotaxane hydrogels, which showed mechanochromic responsiveness in the presence of the integrated fluorophores.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Heat Transfer of Supercritical Carbon Dioxide in 3D-Printed Tubes with Internal Ribs and Yttria Stabilized Zirconia Coating
This technical report describes measurements performed in NETL’s Heat Exchanger Experimental Test (HEET) facility using supercritical carbon dioxide as the working fluid. 3D printed tubes with internal ribs and yttria stabilized zirconia (YSZ) exterior coatings were employed in the heat exchanger. Heat transfer and friction factor enhancements from the internal ribs were characterized over a range of flow conditions. Additionally, the thermal resistance from the YSZ coating was characterized for both a freshly applied coating and a coating subjected to thermal aging.
36 MATERIALS SCIENCE↗