W5170124C0263

Small Business Innovation Research Program (SBIR) Phase I

A modular solid-state additive manufacturing technology to rapidly increase on-demand manufacturing capacity

Metal additive manufacturing (AM) is capable of mitigating supply chain risks for defense manufacturing and fleet maintenance. An affordable and versatile metal AM technology can be a powerful tool to warfighters at the point of need. However, fusion-based metal AM processes are not suitable for high-strength aluminum alloys that are currently used in light weight armors due to their hot cracking susceptibility. Particularly, friction-based AM technologies are suitable for 3D printing large structures in ambient atmosphere with wrought metal microstructure, and offer several advantages over fusion-based, spray-based and ultrasonic-based AM technologies. However, the current state-of-the-art friction-based AM processes suffer from several inherent disadvantages that restrict their usefulness. Development of a modular version of SolidStir AM technology solves the current issues while it can help increase the manufacturing capacity rapidly without substantial capital investment for contested logistics and sustainment. The unique features of SolidStir technology can be used for manufacturing and repairing of various components by utilizing end-of-life components and machined chips leftover from the manufacturing as feedstock. Development of this technology widens the solid-state AM applications and strengthens US manufacturing ECO system. Further, the proposed technology is environmentally friendly, energy efficient and industrial clean technology.

The goal of phase I is to establish the technical merit, feasibility, and commercial potential of proposed R&D efforts and determine the quality of performance of the small business awardee organization.

A244-P001

A244-P001-0456

24.4

Steven Taulbee