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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

In-Operando Study of Shape Retention and Microstructure Development in a Hydrolyzing Sol–Gel Ink during 3D-Printing

3D printing of amorphous and crystalline ceramics is of paramount importance for the fabrication of a wide range of devices with applications across different technology fields. Printed ceramics are remarkably enabled by the sol-gel synthesis method in conjunction with continuous filament direct ink writing. During printing, multiple processes contribute to the evolution of inks including shape retention, chemical conversion, solidification, and microstructure formation. Traditionally, depending on the ink composition and printing environment, several mechanisms have been associated with the shape retention and solidification of 3D printed structures: gelation, rapid solvent evaporation, energy-driven phase transformation, and chemical-driven phase transformation. Understanding the fundamental differences between these mechanisms becomes key since they strongly influence the spatiotemporal evolution of the materials, as the out-of-equilibrium processes inherent to the extrusion, relaxation, and solidification of printed materials have significant effects on the materials properties. Herein, we investigate the shape retention mechanism and the hydrolysis-induced material conversion and microstructure formation during the 3D printing of a water reactive sol-gel ink that transforms into titanium dioxide-based ceramic. This study aims at identifying characteristic mechanisms associated with the material transformation, establishing connections between the microstructure development and the timescales associated with solidification under operando 3D-printing conditions. The investigation of this material's out-of-equilibrium pathways under processing conditions is enabled by time-resolved coherent X-ray scattering, providing simultaneous access to temporospatially resolved microstructural and dynamics information. Furthermore, we explore X-ray speckle tracking as a tool to resolve deformations of the microstructure in a printed filament associated with the deposition of consecutive filaments. Through this work, we aim at providing a fundamental understanding of the relationships behind these transformative processes in 3D printing and their timescales as the basis for achieving unprecedented control over printed materials microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Integrating helicoid channels for passive control of fiber alignment in direct-write 3D printing

3D printing of fiber-reinforced composites has been receiving increasing attention as an efficient additive approach enabling lightweight, functional, and high-performance components required for industrial applications. The properties of fiber composites significantly depend on internal microstructures, including fiber orientation, distribution, and degree of alignment. Although multiple strategies have been introduced for controlling the fiber composites microstructures, these strategies are mostly active approaches relying on additional control of mechatronics parts, external forces, or intentionally introduced unstable flows inside narrow nozzles. These methods suffer from higher risk of nozzle clogging and requiring extra parts in 3D printing. Here, we introduce helicoid channels into extrusion system as a passive approach to control the fiber alignment without any additional moving parts in direct-write 3D printing. The helicoid channels automatically guide the composite inks and align fibers before flowing into narrow nozzle space, avoiding clogging and improving printability. The analyses indicate that both helicoid surface to volume ratio and helix angle affect the pre-alignment of fibers, leading to tunable mechanical properties of printed fiber-reinforced composites with increased stiffness and strength up to 77.6% and 47.8%, respectively.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Active Mixing of Disparate Inks for Multimaterial 3D Printing

3D printing of multimaterial parts relies upon efficient mixing of the ink components and a rapid response to composition changes. However, at low Reynolds numbers and large Peclet numbers, mixing disparate viscosity and density inks poses a challenge. In this study, the performance of active micromixers for disparate non-Newtonian inks is evaluated using both experiments and computational fluid dynamics simulations. The mixing efficiencies are compared with scaling relationships for active micromixers. Using detailed simulation results, multiple factors are identified that can impact the micromixer response time during a composition change. Finally, an active micromixer is proposed and evaluated to efficiently mix arbitrary multimaterial ink compositions and produce fine composition gradients within printed parts.

3D printing↗
DOE OSTI2015

Development and Optimization of Viable Human Platforms through 3D Printing

3D printing technology offers a unique method for creating cell cultures in a manner far more conducive to accurate representation of human tissues and systems. Here we print cellular structures capable of forming vascular networks and exhibiting qualities of natural tissues and human systems. This allows for cheaper and readily available sources for further study of biological and pharmaceutical agents.

42 ENGINEERING↗
DOE OSTI2017

3D printing technologies for electrochemical energy storage

Fabrication of electrodes and electrolytes play an important role in promoting the performance of electrochemical energy storage (EES) devices such as batteries and supercapacitors. Traditional fabrication techniques have limited capability in controlling the geometry and architecture of the electrode and solid-state electrolytes, which would otherwise compromise the performance. 3D printing, a disruptive manufacturing technology, has emerged as an innovative approach to fabricating EES devices from nanoscale to macroscale and from nanowatt to megawatt, providing great opportunities to accurately control device geometry (e.g., dimension, porosity, morphology) and structure with enhanced specific energy and power densities. Moreover, the additive manufacturing nature of 3D printing provides excellent controllability of the electrode thickness with much simplified process in a cost effective manner. With the unique spatial and temporal material manipulation capability, 3D printing can integrate multiple nanomaterials in the same print, and multi-functional EES devices (including functional gradient devices) can be fabricated. Herein, we review recent advances in 3D printing of EES devices. We focused on two major 3D printing technologies including direct writing and inkjet printing. The direct material deposition characteristics of these two processes enable them to print on a variety of flat substrates, even a conformal one, well suiting them to applications such as wearable devices and on-chip integrations. Other potential 3D printing techniques such as freeze nano-printing, stereolithography, fused deposition modeling, binder jetting, laminated object manufacturing, and metal 3D printing are also introduced. The advantages and limitations of each 3D printing technology are extensively discussed. More importantly, we provide a perspective on how to integrate the emerging 3D printing with existing technologies to create structures over multiple length scale from macro to nano for EES applications.

3D printing↗
DOE OSTI2024

Advanced Permanent Magnet Generator Topologies Using Multimaterial Shape Optimization and 3D Printing: Preprint

A vast majority of utility-scale wind turbine generators in the United States are dependent on foreign- sourced rare-earth permanent magnets that are vulnerable to supply chain uncertainties. Many small wind original equipment manufacturers are motivated to pursue continuous improvements to the generator design to lower the material and production costs and improve performance by lowering cogging torque and increasing the efficiency. Traditional design and manufacturing offer limited opportunities. In this work, we demonstrate advanced design approaches for a 15-kW baseline wind turbine generator by making use of recent progress in three-dimensional (3D) printing of polymer- bonded magnets and, electrical and structural steel. We explore three methods of magnet parametrization using Bezier curves resulting in symmetric, asymmetric and multimaterial magnet designs. We employ a multiphysics approach combining parametric computer-aided design modeling, finite- element analysis and targeted sampling to identify novel designs with more opportunities for reducing rare-earth material, improving efficiency and minimizing cogging torque. The results show that asymmetric-pole design and multimaterial-pole designs offer a greater opportunity to minimize rare-earth magnet materials by up to 35% with similar performance as the baseline generator, suggesting newer opportunities with design freedom beyond traditional limits of symmetry and as allowed by 3D printing.

Bezier curves↗
DOE OSTI2014

MO-A-9A-01: Innovation in Medical Physics Practice: 3D Printing Applications

3D printing, also called additive manufacturing, has great potential to advance the field of medicine. Many medical uses have been exhibited from facial reconstruction to the repair of pulmonary obstructions. The strength of 3D printing is to quickly convert a 3D computer model into a physical object. Medical use of 3D models is already ubiquitous with technologies such as computed tomography and magnetic resonance imaging. Thus tailoring 3D printing technology to medical functions has the potential to impact patient care. This session will discuss applications to the field of Medical Physics. Topics discussed will include introduction to 3D printing methods as well as examples of real-world uses of 3D printing spanning clinical and research practice in diagnostic imaging and radiation therapy. The session will also compare 3D printing to other manufacturing processes and discuss a variety of uses of 3D printing technology outside the field of Medical Physics. Learning Objectives: Understand the technologies available for 3D Printing Understand methods to generate 3D models Identify the benefits and drawbacks to rapid prototyping / 3D Printing Understand the potential issues related to clinical use of 3D Printing.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2023

Hierarchically Templated Synthesis of 3D‐Printed Crosslinked Cyclodextrins for Lycopene Harvesting

Abstract Plants produce a wide range of bioactive phytochemicals, such as antioxidants and vitamins, which play crucial roles in aging prevention, inflammation reduction, and reducing the risk of cancer. Selectively harvesting these phytochemicals, such as lycopene, from tomatoes through the adsorption method is cost‐effective and energy efficient. In this work, a templated synthesis of 3D‐printed crosslinked cyclodextrin polymers featuring nanotubular structures for highly selective lycopene harvesting is reported. Polypseudorotaxanes formed by triethoxysilane‐based telechelic polyethylene glycols and α‐cyclodextrins (α‐CDs) are designed as the template to (1) synthetically access urethane‐based nanotubular structures at the molecular level, and (2) construct 3D‐printed architectures with designed macroscale voids. The polypseudorotaxane hydrogels showed good rheological properties for direct ink writing, and the 3D‐printed hydrogels were converted to the desired α‐CD polymer network through a three‐step postprinting transformation. The obtained urethane‐crosslinked α‐CD monoliths possess nanotubular structures and 3D‐printed voids. They selectively adsorb lycopene from raw tomato juice, protecting lycopene from photo‐ or thermo‐degradations. This work highlights the hierarchically templated synthesis approach in developing functional 3D‐printing materials by connecting the bottom‐up molecular assembly and synthesis with the top‐down 3D architecture control and fabrication.

Chemistry↗
DOE OSTI2016

SU-G-BRB-01: A Novel 3D Printed Patient-Specific Phantom for Spine SBRT Quality Assurance: Comparison of 3D Printing Techniques

Purpose: The novel 3 dimensional (3D)-printed spine quality assurance (QA) phantoms generated by two different 3D-printing technologies, digital light processing (DLP) and Polyjet, were developed and evaluated for spine stereotactic body radiation treatment (SBRT). Methods: The developed 3D-printed spine QA phantom consisted of an acrylic body and a 3D-printed spine phantom. DLP and Polyjet 3D printers using the high-density acrylic polymer were employed to produce spine-shaped phantoms based on CT images. To verify dosimetric effects, the novel phantom was made it enable to insert films between each slabs of acrylic body phantom. Also, for measuring internal dose of spine, 3D-printed spine phantom was designed as divided laterally exactly in half. Image fusion was performed to evaluate the reproducibility of our phantom, and the Hounsfield unit (HU) was measured based on each CT image. Intensity-modulated radiotherapy plans to deliver a fraction of a 16 Gy dose to a planning target volume (PTV) based on the two 3D-printing techniques were compared for target coverage and normal organ-sparing. Results: Image fusion demonstrated good reproducibility of the fabricated spine QA phantom. The HU values of the DLP- and Polyjet-printed spine vertebrae differed by 54.3 on average. The PTV Dmax dose for the DLP-generated phantom was about 1.488 Gy higher than for the Polyjet-generated phantom. The organs at risk received a lower dose when the DLP technique was used than when the Polyjet technique was used. Conclusion: This study confirmed that a novel 3D-printed phantom mimicking a high-density organ can be created based on CT images, and that a developed 3D-printed spine phantom could be utilized in patient-specific QA for SBRT. Despite using the same main material, DLP and Polyjet yielded different HU values. Therefore, the printing technique and materials must be carefully chosen in order to accurately produce a patient-specific QA phantom.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2016

Progress in 3D Printing of Carbon Materials for Energy‐Related Applications

The additive‐manufacturing (AM) technique, known as three‐dimensional (3D) printing, has attracted much attention in industry and academia in recent years. 3D printing has been developed for a variety of applications. Printable inks are the most important component for 3D printing, and are related to the materials, the printing method, and the structures of the final 3D‐printed products. Carbon materials, due to their good chemical stability and versatile nanostructure, have been widely used in 3D printing for different applications. Good inks are mainly based on volatile solutions having carbon materials as fillers such as graphene oxide (GO), carbon nanotubes (CNT), carbon blacks, and solvent, as well as polymers and other additives. Studies of carbon materials in 3D printing, especially GO‐based materials, have been extensively reported for energy‐related applications. In these circumstances, understanding the very recent developments of 3D‐printed carbon materials and their extended applications to address energy‐related challenges and bring new concepts for material designs are becoming urgent and important. Here, recent developments in 3D printing of emerging devices for energy‐related applications are reviewed, including energy‐storage applications, electronic circuits, and thermal‐energy applications at high temperature. To close, a conclusion and outlook are provided, pointing out future designs and developments of 3D‐printing technology based on carbon materials for energy‐related applications and beyond.

Fu, Kun↗
DOE OSTI2018

Chemically Active, Porous 3D-Printed Thermoplastic Composites

Metal-organic frameworks (MOFs) exhibit exceptional properties and are widely investigated because of their structural and functional versatility relevant to catalysis, separations, and sensing applications. However, their commercial or large-scale application is often limited by their powder forms. To address this, we report the production of MOF-thermoplastic polymer composites accessed via a standard 3D printer. MOFs (Zeolitic imidazolate framework; ZIF-8) were successfully incorporated homogeneously into both poly(lactic acid) (PLA) and thermoplastic polyurethane (TPU) matrices, extruded into filaments, and utilized for on-demand access to 3D structures by fused-deposition modeling. Printed rigid PLA-MOF composites displayed good structural integrity, high surface area ((SA)avg = 531 m2 g-1) and hierarchical pore features. Flexible TPU-MOF composites (SAavg = 706 m2 g-1) were achieved by employing a sacrificial fluoropolymer readily removed post-printing. Critically, embedded particles in the plastic matrices retain their ability to participate in chemical interactions characteristic of the parent MOF. The fabrication strategies can be extended to other MOFs and illustrate the potential of 3D printing to create unique porous and high surface area chemically-active structures.

Additive Manufacturing, Metal-Organic Framework, 3↗