Advanced Prediction of Polymer Performance

OUSD (R&E) CRITICAL TECHNOLOGY AREA(S): Advanced Materials OBJECTIVE: To provide validated data and tools for the prediction of fatigue performance of parts printed from AF approved polymers. To provide training to program office engineers on the use of the prediction tools, their limitations and validation approaches to guide testing and approval of parts for use. DESCRIPTION: Develop a mechanical behavior model that accounts for the anisotropy of a fused filament fabricated material. PHASE I: PHASE I: This topic is intended for technology proven ready to move directly into a Phase II. Therefore, a Phase I award is not required. The offeror is required to provide detail and documentation in the Direct to Phase II proposal which demonstrates accomplishment of a Phase I-type effort, including a feasibility study. This includes determining the scientific and technical merit and feasibility of ideas appearing to have commercial potential. This feasibility study must include an assessment of the state of the autonomous and adaptive repair processes and how offeror's innovations contribute to cost and schedule reductions for labor costs, material costs, and non-recurring engineering costs. This assessment should validate the product-market fit between the proposed solution and a potential AF stakeholder. The offeror should have defined a clear, immediately actionable plan with the proposed solution and the AF customer. PHASE II: Develop a mechanical behavior model that accounts for the anisotropy of a fused filament fabricated material. The materials of interest are ULTEM 9085 and Antero 800NA. Integrate fatigue analysis capability into the model. Develop S-basis material property database for chopped carbon fiber reinforced FFF material of interest. Manufacture and test geometries representative of AF components in the materials noted above. Evaluate models efficacy on predicting size effects of FFF components and materials. PHASE III DUAL USE APPLICATIONS: The contractor will pursue commercialization of the various technologies developed in Phase II for transition, to include a broad range of potential government and civilian users and alternate applications. Direct access with end users and government customers will be provided with opportunities to receive Phase III awards for providing the government additional research & development, or direct procurement of products and services developed in coordination with the program. REFERENCES: 1. Fatigue of Materials and Structures, Claude Bathias and Andre Pineau, 2008 2. ASTM D7774 Standard Test Method for Flexural Fatigue Properties of Plastics, American Society of Testing and Materials, 2022 3. High cycle fatigue behavior and thermal properties of PLA/PCL blends produced by fused deposition modeling, Kiani et.al, J Polymer Research v30, 7 2023. KEYWORDS: Additive Manufacturing, PEKK; Fused Deposition Modeling, PEKK ; PEKK, Fatigue; ULTEM, PEKK;