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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Combining 3D printing of copper current collectors and electrophoretic deposition of electrode materials for structural lithium-ion batteries

Serving as a proof of concept, additive manufacturing and electrophoretic deposition are leveraged in this work to enable structural lithium-ion batteries with load-bearing and energy storage dual functionality. The preparation steps of a complex 3D printed copper current collector, involving the formulation of a photocurable resin formulation, as well as the vat photopolymerization process followed by a precursors-based solution soaking step and thermal post-processing are presented. Compression and microhardness testing onto the resulting 3D printed copper current collector are shown to demonstrate adequate mechanical performance. Electrophoretic deposition of graphite as a negative electrode active material and other additives was then performed onto the 3D printed copper collector, with the intention to demonstrate energy storage functionality. Half-cell electrochemical cycling of the 3D multi-material current collector/negative electrode versus lithium metal finally demonstrates that structural battery components can be successfully obtained through this approach.

25 ENERGY STORAGE↗
DOE OSTI2023

Penetrating and actuating nozzle for extrusion-based 3D printing

An apparatus and device for creating a vertical strengthening feature within a 3D printed article of manufacture for improving mechanical performance in the Z-direction. Fill material is deposited in voids vertically crossing multiple layers during the build of 3D printing. The device includes a penetrating extension that fits within the void to create a vertical strengthening feature via heat and/or extruded fill material. The size and/or movement of the heated extension can impact the void side walls to reflow the build material and blend the layers together within the void side walls.

Kunc, Vlastimil↗
NASA NTRSDate not supplied

Development of Additive Manufacturing Technologies for 3D Printing of Spacecraft Heat Shields

Introduction: Ablative heat shields are an enabling technology for entry into planetary atmospheres. From the PICA heatshields used for several Mars rovers to the carbon phenolic material used for Galileo’s Jupiter entry probe, the heat shield manages the heat load transferred to the payload, protecting the sensitive scientific instruments carried on entry probes. The Additive Manufacturing of Thermal Protection Systems (AMTPS) project, an Early Career Initiative (ECI) funded by NASA’s Space Technology Mission Directorate and led by NASA Johnson Space Center, seeks to develop materials and processes for 3D printing ablative heat shields for spacecraft. Current methods for producing ablative heat shields are extremely labor intensive and re-quire extensive hands-on processes and quality control characterization. Additive manufacturing (AM) offers the possibility of reduced production times, improved reliability, and enhanced performance via graded compositions. Costs will also be reduced by reducing the time and labor required for heat shield production. Direct integration of the heat shield onto the structure during processing simplifies integration and reduces risk. Material Development: A critical challenge for the project is development of a material system that can (1) be printed in a near-net shape process and (2) perform well as an ablator. Achieving printability requires the material to flow under applied pressure, but maintain its shape once extruded from the printer nozzle. Ablative performance is measured by a multitude of markers, including char yield, char strength, thermal conductivity, and recession rate. Furthermore, there are several mechanical and thermal property considerations for vehicle integration including coefficient of thermal expansion (CTE) and residual stress. AM technology will be leveraged to grade the material formulation and properties through the thickness of the heat shield, an architecture not possible with current manufacturing processes. To this end, “robust” material formulations have been pre-pared with higher density for use on the surface where most ablation will occur. “Insulative” material formulations, with lower density and lower thermal conductivity, are prepared for use in the depth of the heat shield. This graded architecture will re-duce the overall mass of the heat shield and reduce costs and/or increase scientific payload capacities. To achieve a material system with the required properties, multiple resins have been investigated in collaboration with NASA Ames Research Center. To tune printability and performance, resin additives were studied to improve flexibility of the cured material while maintaining acceptable ablative performance. Material coupons were printed and studied via a suite of mechanical and thermal characterization methods. Arc jet testing was conducted at NASA Ames Research Center to evaluate ablative performance and thermal protection under conditions expected in atmospheric entry. Manufacturing Scale-Up: A partnership with Oak Ridge National Laboratory (ORNL) aims to enable full-scale fabrication of a 3D printed heat shield. Leveraging expertise in manufacturing and 3D printing at ORNL, a mid-scale manufacturing demonstration unit will be built and tested, using a dual-layer ablative system printed directly onto the titanium structure. Work on robotic system integration is ongoing and efforts to scale up material mixing with a material compound will ensure accurate and homogenous composition. Flight Test: A hypersonic sub-orbital flight test will provide a rigorous test of material performance ranging from ablation, thermal management, and mechanical integrity. Design of the capsule has taken place in collaboration with the University of Kentucky. Data collected from the flight will inform future design efforts in material formulation, printing methodology, and heat shield-capsule integration.

additive manufacturing↗
DOE OSTI2023

3D-Printed Graded Electrode with Ultrahigh MnO 2 Loading for Non-Aqueous Electrochemical Energy Storage

Electrolytic manganese dioxide is one of the promising cathode candidates for electrochemical energy storage devices due to its high redox capacity and ease of synthesis. Yet, high-loading MnO 2 often suffers from sluggish reaction kinetics, especially in non-aqueous electrolytes. The non-uniform deposition of MnO 2 on a porous current collectors also makes it difficult to fully utilize the active materials at high mass loading. Here, a 3D printed graded graphene aerogel (3D GA) that contains sparsely separated exterior ligaments is developed to create large open channels for mass transport as well as densely arranged interior ligaments providing large ion-accessible active surface. The unique structural design homogenizes the thickness of electro deposited MnO 2 even at an ultrahigh mass loading of ≈70 mg cm -2 . The electrode achieves a remarkable volumetric capacity of 29.1 mA h cm -3 in the non-aqueous electrolyte. A Li-ion hybrid capacitor device assembled with a graded 3D GA/MnO2 cathode and graded 3D GA/VO x anode exhibits a wide voltage window of 0–4 V and a superior volumetric energy density of 20.2 W h L -1 . The findings offer guidance on 3D printed electrode design for supporting ultrahigh loading of active materials and developments of high energy density energy storage devices.

electrochemical energy storage↗
DOE OSTI2021

3D printing of thermoset polymers and composites

The present disclosure provides a novel method of 3D printing using frontal polymerization chemistry. This method enables the printing of tough, high quality thermosets in a short time with the option of adding fiber reinforcement. As such, it facilitates fabrication of mechanically robust 3D-printed devices and structures.

Moore, Jeffrey S.↗
DOE OSTI2020

3D Printing of Liquid Crystal Elastomer Foams for Enhanced Energy Dissipation Under Mechanical Insult

Polymer foams are an essential class of lightweight materials used to protect assets against mechanical insults, such as shock and vibration. Two features are important to enhance their energy absorption characteristics: the foam structure and the matrix phase mechanical behavior. This study investigates novel approaches to control both of these features to enhance the energy absorption capability of flexible lattice foams. First, we consider 3D printing via digital light processing (DLP) as a method to control the foam mesostructure across a suite of periodic unit cells. Second, we introduce an additional energy dissipation mechanism in the solid matrix phase material by 3D printing the lattice foams with polydomain liquid crystal elastomer (LCE), which undergo a mechanically induced phase transition under large strains. This phase transition is associated with LC mesogen rotation and alignment and provides a second mechanism for mechanical energy dissipation in addition to the viscoelastic relaxation of the polymer network. Here, we contrast the 3D printed LCE lattices with conventional, thermomechanically near-equivalent elastomer lattice foams to quantify the energy-absorbing enhancement the LCE matrix phase provides. Under cyclic quasi-static uniaxial compression conditions, the LCE lattices show dramatically enhanced energy dissipation in uniaxial compression compared to the non-LCE equivalent foams printed with a commercially available photocurable elastomer resin. The lattice geometry also plays a prominent role in determining the energy dissipation ratio between the LCE and non-LCE foams. We show that when increasing the lattice connectivity, the foam deformation transitions from bending-dominated to stretching-dominated deformations, which generates higher axial strains in the struts and higher energy dissipation in the lattice foam, as stretching allows greater mesogen rotation than bending. The LCE foams demonstrate superior energy absorption during the repeated dynamic loading during drop testing compared with the non-LCE equivalent foams, demonstrating the potential of LCEs to enhance physical protection systems against mechanical impact.

3D printing↗
DOE OSTI2023

Advancements in conventional and 3D printed feed spacers in membrane modules

Plate & frame and spiral-wound modules are used for gas separation, pervaporation, reverse osmosis, nanofiltration, ultrafiltration, microfiltration, electro-dialysis, electro-deionization, membrane distillation and forward osmosis membrane processes. Feed channel spacers are an integral part of both module types – providing mechanical support for a cross-flow channel through the module and, in most cases, promoting mixing to enhance mass transfer to reduce concentration polarization and fouling. However, enhanced mass transfer comes at a cost of increased hydraulic pressure losses and stagnant zones wherever a spacer filament touches a membrane surface. Further, these stagnant zones exacerbate membrane fouling and make cleaning more difficult. Efforts to improve feed spacer performance largely focus on adjusting the chemistry or geometry of the spacer to mitigate these challenges. Additive manufacturing (i.e. 3D printing) offers new degrees of freedom in feed spacer design and production, which opens up a new area of research in membrane technology. This review critically assesses the peer-reviewed literature on conventional net- or mesh-style feed spacers in addition to various novel spacer geometries and chemistries produced via 3D printing. We further review and evaluate conventional spacer manufacturing methods and discuss advantages and disadvantages of 3D printed spacers.

3D printing↗
DOE OSTI2021

3D Printed Nickel–Molybdenum-Based Electrocatalysts for Hydrogen Evolution at Low Overpotentials in a Flow-Through Configuration

Three-dimensional (3D) printed, hierarchically porous nickel molybdenum (NiMo) electrocatalysts were synthesized and evaluated in a flow-through configuration for the hydrogen evolution reaction (HER) in 1.0 M KOH(aq) in a simple electrochemical H-cell. 3D NiMo electrodes possess hierarchically porous structures because of the resol-based aerogel precursor, which generates superporous carbon aerogel as a catalyst support. Relative to a traditional planar electrode configuration, the flow-through configuration allowed efficient removal of the hydrogen bubbles from the catalyst surface, especially at high operating current densities, and significantly decreased the overpotentials required for HER. An analytical model that accounted for the electrokinetics of HER as well as the mass transport with or without the flow-through configuration was developed to quantitatively evaluate voltage losses associated with kinetic overpotentials and ohmic resistance due to bubble formation in the porous electrodes. Furthermore, the chemical composition, electrochemical surface area (ECSA), and roughness factor (RF) were also systematically studied to assess the electrocatalytic performance of the 3D printed, hierarchically porous NiMo electrodes. An ECSA of 25163 cm2 was obtained with the highly porous structures, and an average overpotential of 45 mV at 10 mA cm–2 was achieved over 24 h by using the flow-through configuration. The flow-through configuration evaluated in the simple H-cell achieved high electrochemical accessible surface areas for electrochemical reactions and provided useful information for adaption of the porous electrodes in flow cells.

08 HYDROGEN↗
DOE OSTI2022

Design and construction of 3D printed devices to investigate active and passive bacterial dispersal on hydrated surfaces

Background: To disperse in water-unsaturated environments, such as the soil, bacteria rely on the availability and structure of water films forming on biotic and abiotic surfaces, and, especially, along fungal mycelia. Dispersal along such “fungal highways” may be driven both by mycelial physical properties and by interactions between bacteria and fungi. However, we still do not have a way to disentangle the biotic and abiotic elements. Results: We designed and 3D printed two devices establishing stable liquid films that support bacteria dispersal in the absence of biotic interactions. The thickness of the liquid film determined the presence of hydraulic flow capable of transporting non-motile cells. In the absence of flow, only motile cells can disperse in the presence of an energy source. Non-motile cells could not disperse autonomously without flow but dispersed as “hitchhikers” when co-inoculated with motile cells. Conclusions: The 3D printed devices can be used as an abiotic control to study bacterial dispersal on hydrated surfaces, such as plant roots and fungal hyphae networks in the soil. By teasing apart the abiotic and biotic dimensions, these 3D printed devices will stimulate further research on microbial dispersal in soil and other water-unsaturated environments.

3D printing↗
DOE OSTI2025

Target fabrication fields first NIF shot with new 3D-printed microfluidic target design

Capable of producing ultrafine features, two-photon polymerization (2PP) 3D printing made it possible to field a first-of-its-kind leak-proof liquid-filled diffraction target. These targets are used for shots aimed at using laser pressure instead of low temperatures turn water into ice. The shot is the product of months of design, assembly, and installation work by LSEO’s target fabrication team, in collaboration with 3D printing experts Widi Moestopo (MED) and Xiaoxing Xia (MED) and PLS researcher Neal Bhandarkar.

42 ENGINEERING↗
DOE OSTI2026

Graphene oxide precursor effects on 3D-printed carbon scaffolds

Manganese oxide (MnO 2 ), an earth-abundant material, is a promising component for energy storage devices, with uses in both pseudocapacitors and batteries. However, high MnO 2 loading often leads to reduced performance due to poor ion diffusion. 3D printing, particularly using the direct ink writing (DIW) technique, offers a solution by enabling the fabrication of electrodes with hierarchical porous structures and open channels that enhance mass transport and ion diffusion. Previous work demonstrated that 3D-printed graphene aerogels with MnO 2 coatings exhibited excellent electrochemical performance, even with thick electrodes, due to their optimized structure. Building on this work, the current study investigates the performance differences between aerogels developed using graphene oxide (GO) and reduced graphene oxide (rGO) as carbon precursors. Both materials were incorporated into thixotropic inks, 3D-printed into lattice structures, and carbonized. Despite expected similarities between the final graphene aerogel, rGO-based aerogels exhibited superior areal capacitance, compared to GO-based aerogels. These differences are attributed to the lower oxygen content and defect density of rGO, which influence its interaction with cellulose viscosifiers in the ink formulation. Brunauer–Emmett–Teller (BET) surface area analysis revealed that rGO aerogels exhibit a larger surface area and mesoporous structure, further enhancing their performance. When coated with MnO 2 , rGO-based aerogels maintained their superior capacitive behavior over GO-based aerogels. This study highlights the effect of carbon precursor on the end performance of graphene aerogels.

Materials science↗
DOE OSTI2021

A novel lung-inspired 3D-printed desiccant-coated heat exchanger for high-performance humidity management in buildings

Offering an independent humidity management method for buildings, desiccant-coated heat exchangers (DCHXs) are deemed a promising approach to improve the overall energy efficiency of air conditioning (AC) systems. State-of-the-art DCHXs, however, are bound with conventional HX topologies either providing limited desiccant-air interfacial areas or introducing excessive pressure drop penalties. In this paper a novel 3D-printed DCHX concept inspired by the bronchi arrangement of a human lung is introduced to address the shortcomings inherent in existing DCHX designs. The proposed lung-inspired DCHX utilizes two intertwined bicontinuous flow networks enabling highly efficient heat and mass transfer characteristics for augmented adsorption and regeneration processes at low pressure drop penalties. While the first network evenly distributes an incoming air stream through the entire volume of the lung-inspired DCHX, the second network volumetrically splits a cooling water stream within and through the first network. Effects of various parameters including air flow rate, outdoor air humidity ratio, and regeneration temperature on dehumidification performance and energy efficiency of the proposed lung-inspired DCHX were investigated. Experimental results indicated the proposed lung-inspired 3D-printed DCHX outperforms existing DCHX systems by demonstrating an excellent balance between a high volumetric adsorption rate and a low pressure drop penalty. The volumetric adsorption rate of the proposed lung-inspired DCHX technology is 54.8 g/m 3 -s, a more than two-fold improvement compared with state-of-the-art DCHX systems. Additionally, the lung-inspired DCHX offers high thermal energy efficiency of 56% at a low regeneration temperature of 40 °C. Therefore, the proposed lung-inspired 3D-printed DCHX offers a new solid-desiccant-based air dehumidification pathway for next-generation high-performance AC systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

3D printing of ceramics: Advantages, challenges, applications, and perspectives

Abstract 3D printing (3DP) technologies have transformed the processing of advanced ceramics for small‐scale and custom designs during the past three decades. Simple and complex parts are designed and manufactured using 3DP technologies for structural, piezoelectric, and biomedical applications. Manufacturing simple or complex geometries or one‐of‐a‐kind components without part‐specific tooling saves significant time and creates new applications for advanced ceramic materials. Although development and innovations in 3DP of ceramics are far behind compared with metals or polymers, with the availability of different commercial machines in recent years for 3DP of ceramics, exponential growth is expected in this field in the coming decade. This article details various 3DP technologies for advanced ceramic materials, their advantages and challenges for manufacturing parts for various applications, and perspectives on future directions. We envision this work will be helpful to advanced ceramic researchers in industry and academia who are using different 3DP processes in the coming days.

36 MATERIALS SCIENCE↗
NASA NTRS2019

Electrical and Thermal Characterization of 3D Printed Thermoplastic Parts with Embedded Wires for High Current-Carrying Applications

Fabrication of parts exhibiting multi-functionality has recently been complemented by hybrid polymer extrusion additive manufacturing in combination with wire embedding technology. While much mechanical characterization has been performed on parts produced with fused deposition modeling, limited characterization has been performed when combined electrical and thermal loads are applied to 3D printed multi-material parts. As such, this work describes the design, fabrication, and testing of 3D printed thermoplastic coupons containing embedded copper wires that carried current. An automated fabrication process was used employing a hybrid additive manufacturing machine that dispensed polycarbonate thermoplastic and embedded bare copper wires. Testing included AC and DC hipot testing as well as thermal testing on as-fabricated and heat treated coupons to determine the effect of porosity in the substrate. The heat-treated parts contained reduced amounts of porosity, as corroborated through scanning electron microscopy, which led to 50 % increased breakdown strength and 30 to 40 % increased heat dissipation capabilities. The results of this research are describing a set of design protocol that can be used as a guideline for 3D printed embedded electronics to predict the electrical and thermal behavior.

Hipot testing↗
DOE OSTI2022

3D Printing at Los Alamos

At Los Alamos National Laboratory (LANL), their additive manufacturing division is seeking to answer the question whether it is possible to 3D print on a 5th axis. The end goal is to achieve true continuous fiber 3D printing. My goal on this project was to learn about additive manufacturing, and to learn how to operate the experimental 3D printer. Each print that was done demonstrated a different pattern that would change the strength and integrity of the print. Overall prints with minimal strand separation and featured weave-like patterns proved to have the best integrity.

42 ENGINEERING↗