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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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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Towards P3HT Inkjet Printability of Sensors

Here we propose a method to inkjet print sensors using P3HT and present the data that demonstrates the printability potential of this material. Poly(3-Hexylthiophene) commonly known as P3HT is a semiconductor polymer that is usually used as a hole transporting material in the fabrication of transistors, and perovskite solar cells. There is a desire to transpose this technology to inkjet printing to ease the testing and researching of semiconductor polymers. However, there has been not success in the inkjet printability of P3HT due to the lack of key information such as viscosity and surface tension and the additional issues of using a strong solvent to dilute P3HT. In this work we propose a method to inkjet print P3HT sensors using a commercially available inkjet printer. This method is reinforced with the measurements obtained from a viscometer and surface tensiometer.

Marquez, Jesus↗
DOE OSTI2021

Methods and devices for fabricating and assembling printable semiconductor elements

The invention provides methods and devices for fabricating printable semiconductor elements and assembling printable semiconductor elements onto substrate surfaces. Methods, devices and device components of the present invention are capable of generating a wide range of flexible electronic and optoelectronic devices and arrays of devices on substrates comprising polymeric materials. The present invention also provides stretchable semiconductor structures and stretchable electronic devices capable of good performance in stretched configurations.

Nuzzo, Ralph G.↗
DOE OSTI2021

3D-Printable Fluoropolymer Gas Diffusion Layers for CO 2 Electroreduction

The electrosynthesis of value-added multicarbon products from CO 2 is a promising strategy to shift chemical production away from fossil fuels. Particularly important is the rational design of gas diffusion electrode (GDE) assemblies to react selectively, at scale, and at high rates. However, the understanding of the gas diffusion layer (GDL) in these assemblies is limited for the CO 2 reduction reaction (CO 2 RR): particularly important, but incompletely understood, is how the GDL modulates product distributions of catalysts operating in high current density regimes > 300 mA cm -2 . Here, 3D-printable fluoropolymer GDLs with tunable microporosity and structure are reported and probe the effects of permeance, microstructural porosity, macrostructure, and surface morphology. Under a given choice of applied electrochemical potential and electrolyte, a 100× increase in the C 2 H 4 :CO ratio due to GDL surface morphology design over a homogeneously porous equivalent and a 1.8× increase in the C 2 H 4 partial current density due to a pyramidal macrostructure are observed. Overall, these findings offer routes to improve CO 2 RR GDEs as a platform for 3D catalyst design.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Quasi‐2D Perovskite Crystalline Layers for Printable Direct Conversion X‐Ray Imaging

Abstract Polycrystalline perovskite film‐based X‐ray detector is an appealing technology for assembling large scale imager by printing methods. However, thick crystalline layer without trap and solvent residual is challenging to fabricate. Here, the authors report a solution method to produce high quality quasi‐2D perovskite crystalline layers and detectors that are suitable for X‐ray imaging. By introducing n ‐butylamine iodide into methylammonium lead iodide precursor and coating at elevated temperatures, compact and crystalline layers with exceptional uniformity are obtained on both rigid and flexible substrates. Photodiodes built with the quasi‐2D layers exhibit a low dark current and stable operation under constant electrical field over 96 h in dark, and over 15 h under X‐ray irradiation. The detector responds sensitively under X‐ray, delivering a high sensitivity of 1214 µC Gy air −1 cm −2 and a sensitivity gain is observed when operated under higher fields. Finally, high resolution images are demonstrated using a single pixel device that can resolve 80–200 µm features. This work paves the path for printable direct conversion X‐ray imager development.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Refractive Index and Abbe Number Tuning via 3D Printable Optical Quality Silica–Titania–Germania Glasses

The development of optical quality GeO 2 –TiO 2 –SiO 2 glasses compatible with direct ink writing (DIW) 3D printing is reported in this study. Colloidal GeO 2 and TiO 2 –SiO 2 core–shell feedstocks are prepared by a sol–gel method and converted to printable inks for DIW. Printed inks are subsequently densified to glass using heat treatment at temperatures up to 1100 °C in air. A series of print‐compatible glass compositions are prepared, yielding transparent glass with the highest refractive index n = 1.576. Herein, it is shown that more TiO 2 can be incorporated into the glass without haziness or scattering through the addition of GeO 2 . The mechanisms for this are discussed, and it is shown that crystallization persists in these glasses despite the lack of visible light scattering. Finally, the combination of both TiO 2 and GeO 2 into a ternary glass also is used to independently tune the dispersion properties of the glass, as demonstrated by measured refractive indices and Abbe numbers, which has potential implications for 3D‐printed optics.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A Sustainable Multi-Dimensional Printable Material

Polymeric materials are usually tailored for specific functionality. A single polymer exhibiting multiple simultaneous functionalities often requires intricate molecular architecture, which is difficult to manufacture at scale because of its complex synthesis routes. In this work, a facile, partly renewable composition—prepared via reactive melt processing—that induces tunable functionalities such as 3D printability, shape recovery, and self-healing while exhibiting satisfactory mechanical properties is reported. The system with a hydrogen-bonded 3D network consists of thermally reversible nano-scale agglomerates of sustainable, rigid phenolic oligomers and crystallizable flexible polymer. Local molecular mobility and temperature-dependent relaxation and recovery of the non-equilibrium networked states enable exploiting these simultaneous functionalities. Transitions involving solidification and structure stabilization at ambient temperature spanning several hours after preheating only at 70 °C directly contrast typical thermoplastic or thermoplastic elastomer behaviors. Results from this study can inform the design of future rheology modifiers and materials for soft robotics.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Ageing of PBF‐Grade Poly(Phenylene Sulfide) Powder and its Effect on Critical Printability Properties

Abstract Poly(phenylene sulfide) (PPS) is a high‐performance polymer suiting the needs of powder bed fusion (PBF) early‐adopter industries. Although there are many benefits to PBF's powder bed‐based, one drawback is thermal ageing of the powder not incorporated into printed parts. Ideally, unfused powder can be reused in future builds; however, it is unlikely that critical printability properties of the thermally aged powder will remain unchanged. Changes in properties lead to either limited reuse through a practice of mixing used and new powder, or elimination of all powder after each build. In this paper, the authors report effects of thermal ageing in simulated printing conditions on properties of PPS critical to PBF processing. PBF‐grade PPS powder is exposed to process‐mimicking conditions. Properties relevant to the three PBF manufacturing process sub‐functions are assessed for the aged powders. Single‐layer prints are made using aged powder to observe polymer‐PBF interactions ad machina. Significant and systematic deviations from the as‐received state of the powder are observed for thermal and coalescence related properties with increasing exposure time and temperature. These changes are interpreted both in terms of physical and chemical changes in PPS and in terms of how these changes may impact the PBF printing process.

Chatham, Camden A.↗
DOE OSTI2021

Compositional effects on cure kinetics, mechanical properties and printability of dual-cure epoxy/acrylate resins for DIW additive manufacturing

Interest in 3D printing of thermoset resins has increased significantly in recent years. One approach to additive manufacturing of thermoset resins is printing dual-cure resins with direct ink write (DIW). Dual-cure resins are multi-component resins which employ an in situ curable constituent to enable net-shape fabrication while a second constituent and cure mechanism contribute to the final mechanical properties of the printed materials. In this work, the cure kinetics, green strength, printability, and print fidelity of dual-cure epoxy/acrylate thermoset resins are investigated. Resin properties are evaluated as a function of acrylate concentration and in situ UV exposure conditions. The acrylate cure kinetics are probed using photo-differential scanning calorimetry and the impacts of resin composition and UV cure profile on the acrylate extent of conversion are presented. Continuous and pulsed UV cure profiles are shown to affect total conversion due to variances in radical efficiency at different UV intensities and acrylate concentrations. The effects of acrylate concentration on the kinetics of the epoxy thermal cure and the final mechanical properties are also investigated using dynamic mechanical analysis and three-point bend measurements. The glass transition temperature is dependent on formulation, with increasing acrylate content decreasing the T g . However, the room temperature shear moduli, flexural moduli, strength, strain-to-failure, and toughness values are relatively independent of resin composition. The similarity of the final properties allows for greater flexibility in resin formulation and in situ cure parameters, which can enable the printing of complex parts that require high green strength. We found that the in situ UV print intensities and exposure profiles that are necessary to achieve the best print quality are not, in most cases, the conditions that maximize conversion of the acrylate network. Lastly, this highlights the importance of developing optimized resin compositions which enable complete cure of the acrylate network by promoting acrylate dark cure or thermal cure.

36 MATERIALS SCIENCE↗
DOE OSTI2021

3D-printable engineered cementitious composites (3DP-ECC): Fresh and hardened properties

3D printing (3DP) is an emerging digital construction method for concrete materials. A major impediment to efficient 3D concrete printing (3DCP) is the need for steel reinforcement, the placement of which is incompatible with the 3DP process. Unlike plain concrete, ductile self-reinforced engineered cementitious composite (ECC) holds promise to remove the dependence on steel reinforcement. The objective of this research is to develop a 3D-printable ECC (3DP-ECC). The fresh rheological and hardened mechanical properties of 3DP-ECC are investigated. The robotically printed tensile specimens demonstrated the familiar multiple microcracking and strain-hardening behavior of conventionally cast ECC. Significant orthotropy is revealed in the compressive properties. The interface between printed layers is found to be toughened by a printed groove-tongue joint. The developed 3DP-ECC was used to print a twisted column with 150 layers, reaching a height of 1.5 m. This research lays the groundwork for efficient robotically 3D-printed structures of complex shapes.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Printable, emissivity-adaptive and albedo-optimized covering for year-round energy saving

Radiative cooling uses high-emissivity materials to passively cool the surface of outdoor objects, such as building roofs on hot days. The issue of overcooling with this technology on cold days can be addressed by structures with thermal emissivity that is adaptive to temperature. Despite recent advances in temperature-adaptive structures, great challenges remain in their fabrication feasibility and unoptimized solar heating that may override the radiative cooling benefit. Here, in this work, we develop a printable, emissivity-adaptive and albedo-optimized covering (PEAC) based on recyclable materials with roll-to-roll fabrication. A PEAC automatically switches its sky-window emissivity from 0.25 to 0.85 when the surface temperature exceeds a pre-set transition temperature, delivering an albedo optimized for maximal year-round energy saving or thermal comfort in a given climate.

36 MATERIALS SCIENCE↗
DOE OSTI2023

3D printable polyvinyltoluene-based plastic scintillators with pulse shape discrimination

A feasibility of preparing bulk photopolymerized plastics scintillators that contain vinyltoluene with multifunctional monomers, pentaerythritol tetraacrylate is shown. This formulation offers a simple and fast way to prepare polyvinyltoluene-based plastics with efficient fast neutron/gamma pulse shape discrimination (PSD) within minutes. 30 wt% of 2,5-diphenyloxazole (PPO) was added in the mixtures of vinyltoluene and pentaerythritol tetraacrylate with different secondary dyes to understand the effect of dyes on the scintillation. Prepared resins were photopolymerized under different conditions, and the scintillation performance was compared to a commercially available standard, EJ-276. Additional functionality for thermal neutron sensitivity was introduced by the incorporation of 6 Li and 6 B nuclei. With optimized conditions, prepared plastics showed light output up to 90% relative to the same size of EJ-276. Here, the best plastic scintillators had PSD figures of merit (FoMs) up to 2.77 compared to 3.25 of EJ-276. The 3D-printability of the tested formulations was demonstrated.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Screen printable copper pastes for silicon solar cells

The current work demonstrates the successful metallization of a PERC silicon solar cell with screen-printable copper (Cu) paste that is sintered at elevated temperature in air atmosphere. The existing state of the art in Silicon (Si) solar cell metallization is silver (Ag) paste; Cu cost is 1/100th the cost of Ag and has a comparable conductivity. However, Cu undergoes rapid oxidation at elevated temperatures and the high diffusion of Cu into Si restricts its usage in the metallization of silicon solar cells. In this paper, a Cu paste containing a proprietary mixture of antioxidant additives and diffusion inhibitors was used to make front gridlines on PERC cells. The Cu-printed cells were fired in an IR belt furnace with a peak temperature of 576°C in air atmosphere. The solar cells discussed here reached an efficiency of 19%, which is 88% of the efficiency measured for a commercial Ag-printed cell. The working devices were further characterized using STEM, EDX, ToF-SIMS and long-term suns-V oc studies demonstrating an absence of Cu diffusion. Furthermore, thermally stressing the Cu-printed solar cells yielded a reduction of less than 1.9% of the initial pseudo fill factor (pFF) after 1000 hours at 200°C. Here, the shunt resistance of cells monitored over 3 years remained within 2.5% of its initial value, which demonstrates the effectiveness of the Cu diffusion barrier.

14 SOLAR ENERGY↗
DOE OSTI2024

Electrostatic Dissipation in 3D-Printable Silicone

Here, in this report, we describe the incorporation of single-walled carbon nanotubes (CNTs) into 3D printable siloxane elastomers for electrostatic dissipation. The composite was characterized, focusing on how rheological and mechanical properties of the siloxane are affected at various CNT loading levels. Electrical properties were also characterized to develop materials with effective electrostatic dissipation. We demonstrate that low loadings (<1 wt %) of CNTs can be sufficiently dispersed into silicone resins that can be 3D printed, and the resulting material shows a significant improvement in electrostatic dissipation through the reduction in electrical resistivity with minimal effect on its mechanical properties.

36 MATERIALS SCIENCE↗
DOE OSTI2021

3D Printable All-Polymer Epoxy Composites

Herein, 3D printable polymer-toughened epoxy resin composites are reported. Epoxy resins are widely used due to their excellent properties, such as thermal and chemical stability. However, their applications are limited by traditional mold-based manufacturing and their high brittleness. Mixtures of homopolymers, diblock copolymers, and triblock copolymers composed of poly(phenylene ether), poly(styrene), poly(methyl methacrylate), and poly(ethylene oxide) that self-assemble into micelles in the uncured resin are employed, providing a balance of structure, creep resistance, and flowability that enables 3D printing processing techniques and a retention of dimensional fidelity from the time of printing throughout the cured state. The precured ink is solid at room temperature and has strong shear-thinning behavior at elevated temperature for printing. As the printed parts cure, the polymer morphology evolves via reaction induced phase separation to yield finished composites with enhanced mechanical properties, including a 40% increase in the impact strength compared to the neat epoxy, without compromising thermal properties.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

N -Terminal Octylated Peptoid Hydrogels as 3D-Printable Cell Scaffolds and Proteolytically Robust Cargo Depots

Supramolecular hydrogels that mimic the extracellular matrix (ECM) represent promising materials for tissue engineering and drug delivery. However, conventional hydrogels formed via the self-assembly of natural or synthetic building blocks often face a trade-off between biological functionality and biochemical stability, limiting their utility in long-term or protease-rich environments. Peptoids, a class of peptide-inspired, sequence-defined polymers, offer a compelling alternative due to their exceptional proteolytic resistance and bioactivity. Despite this potential, the development of supramolecular peptoid hydrogels has been hindered by the absence of backbone hydrogen bond donors, which limits long-range ordering necessary for efficient hydrogel formation. This work describes a short peptoid functionalized at the N-terminus with an octyl chain that readily self-assembles into hydrogels. Hydrophobic interactions among pendant octyl groups promote directional peptoid packing into highly ordered nanosheets, which interconnect to form a porous hydrogel network. These hydrogels exhibit tunable viscoelasticity, shear-thinning, and self-healing properties, enabling their use as inks for extrusion-based 3D printing. They support NIH-3T3 fibroblast adhesion, spreading, and proliferation, maintaining greater than 95% cell viability over 4 days. Moreover, the hydrogels retain their macroscopic integrity under protease-rich conditions, enabling sustained cargo release and uniform cellular uptake. Together, this study demonstrates a class of supramolecular peptoid hydrogelators that integrate biocompatibility, 3D printability, and proteolytic stability, providing a versatile platform for ECMmimetic scaffolds in regenerative medicine and long-term therapeutic delivery.

cargo delivery↗
DOE OSTI2023

Organocatalysis in ring opening copolymerization as a means of tailoring molecular weight dispersity and the subsequent impact on physical properties in 4D printable photopolymers

Vat photopolymerization 3D printing has traditionally relied on free radical crosslinking between alkenes to produce non-degradable parts, which may have limited use in the biomedical and clinical spaces. Photopolymer resins containing functionalized degradable polymers, specifically polyesters, are greatly interesting for 3D printing tissue scaffolds and medical devices. Unfortunately, most polyesters produced for these applications have been made using metal-containing catalysts, which are not without risk for medical applications. Organocatalysis is a viable alternative route to achieving the same types of polyesters. Here, ring opening copolymerization (ROCOP) of allyl and cyclohexene-containing polyesters is examined using bipyridine and a guanidine-containing catalyst. The role of the catalysts, initiators, and cocatalysts are examined for bulk, open air ROCOP reactions. Unlike previous efforts with organocatalysis, the examined catalysts here could be used to tailor the dispersity of the polyesters, with ~10 kDa polyesters with dispersity ranging from 1.3 to 2.5 examined for the impact on rheological and thermomechanical properties related to resin/part behavior. The bipyridine catalysts and a thiourea cocatalyst further are shown, through the introduction of new fluorescence emissions of the purified polyesters. As a result, this work demonstrates that tuning the dispersity of polyester photopolymers provides a direct method of tailoring physical and optical properties in 3D/4D printable materials.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Printability and Overall Cooling Performance of Additively Manufactured Holes With Inlet and Exit Rounding

Abstract To improve cooling effectiveness of gas turbine hardware, various film cooling hole shapes have previously been researched. Unique design modifications have recently been made possible through the design freedom allotted by additive manufacturing (AM). As one example, creating a rounded inlet for a film-cooling hole can mitigate separation at the inlet. This study explores various geometric features by exploiting the uses of additive manufacturing for shaped film cooling holes at engine scale. Both printability and cooling performance were evaluated. Resulting from this study, additively manufactured holes with hole inlet and exit rounding were printed with some variations from the design intent (DI). The largest deviations from the design intent occurred from dross roughness features located on the leeward side of the hole inlet. The measured overall effectiveness indicated that an as-built inlet fillet decreased in-hole convection as well as decreased jet mixing compared to the as-built sharp inlet. Including an exit fillet, which prevented an overbuilt diffuser exit, was also found to decrease jet mixing. A particular insight gained from this study is the importance of the convective cooling within the hole to the overall cooling performance. In-hole roughness, which is a result of additive manufacturing, increased convective cooling within the holes but also increased jet mixing as the coolant exited the hole. The increased jet mixing caused low overall effectiveness downstream of injection.

Engineering↗
DOE OSTI2023

On the 3D printability of silicone-based adhesives via viscous paste extrusion

Silicone, a commonly used household and construction adhesive, filler, or sealant, is also known for its flexibility, thermal stability, and insulating properties. It is viable as a conformally 3D-printed elastomeric matrix for flexible electronics and biomedical applications. Since most of the popular 3D printing methods use precise print specifications and defined resolution, this study explored the 3D printability of commercial silicone adhesives via a paste extrusion setup. Its viscoelastic and composition properties including the dimensional accuracy and mechanical properties of printed objects using controlled print parameters have been investigated. Finally, these experimental processes in 3D printing should pave the way in using materials originally intended for household use.

36 MATERIALS SCIENCE↗