2419486
Project Grant
Overview
Grant Description
SBIR Phase I: Dry powder pressing additive manufacturing (DPP-AM) - The broader/commercial impact of this Small Business Innovation Research (SBIR) Phase I project will be the development of a new additive manufacturing technique for ceramic materials.
Technical ceramics provide unmatched performance in harsh environment applications found throughout the energy, defense, healthcare, and IT sectors.
Applications requiring miniaturization or process intensification would benefit from a novel additive ceramic manufacturing that can form internal microfeatures and combine different materials into functional layers for chemical reactions, imaging, or energy transfer.
This proposal will advance from proof-of-concept to a functional prototype of a dry powder pressing additive manufacturing printer.
This work will improve our understanding of the fluidization and aerosolization of ultrafine and dense nanopowders that are prone to compaction and static adhesion.
The high-resolution from dry powder pressing additive manufacturing will lower monolith fabrication cost an order of magnitude to accelerate the adoption of emerging ceramic technologies.
No existing ceramic production technology can combine multiple functional materials in the same layer or produce internal flow features at the proposed sub-mm scale.
The technology will be leased or sold to advanced ceramic fabricators to enable further technology developments in the ceramics industry.
The manufacturing will first be applied to the energy market, but has the potential to impact defense and health imaging technologies as well.
This Small Business Innovation Research (SBIR) Phase I project seeks to scale the throughput capacity of a dry-powder pressing additive manufacturing technique that can fabricate multifunctional ceramic monoliths with internal flow structures.
Five key capabilities distinguish dry-powder pressing additive manufacturing from existing ceramic additive manufacturing methods:
I) Applicability to materials not amenable to laser sintering,
II) Co-deposition of multiple materials with high lateral precision,
III) Densification of materials typically incapable of pressureless sintering to full density,
IV) A quality control step can reject a layer prior to adhering to prior layers, and
V) Co-deposition of fugitive material can form internal gas routing that eliminates costly and complex ceramic sealing technology in harsh environment applications.
The proposed work will advance the technology by creating a high-throughput printing system to deposit patterned 50 cm² layers in a single pass, representing a 100x throughput increase.
Automation will also address two precision targets; layer deposition below 7.5 mg/cm² and lateral resolution less than 0.5 mm.
The scope of work will advance the science of dry powder deposition and transfer to refine the processing capability for thinner layers and finer microfeatures while simultaneously engineering a high throughput device representative of pilot-scale manufacturing.
This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the foundation's intellectual merit and broader impacts review criteria.
Subawards are not planned for this award.
Technical ceramics provide unmatched performance in harsh environment applications found throughout the energy, defense, healthcare, and IT sectors.
Applications requiring miniaturization or process intensification would benefit from a novel additive ceramic manufacturing that can form internal microfeatures and combine different materials into functional layers for chemical reactions, imaging, or energy transfer.
This proposal will advance from proof-of-concept to a functional prototype of a dry powder pressing additive manufacturing printer.
This work will improve our understanding of the fluidization and aerosolization of ultrafine and dense nanopowders that are prone to compaction and static adhesion.
The high-resolution from dry powder pressing additive manufacturing will lower monolith fabrication cost an order of magnitude to accelerate the adoption of emerging ceramic technologies.
No existing ceramic production technology can combine multiple functional materials in the same layer or produce internal flow features at the proposed sub-mm scale.
The technology will be leased or sold to advanced ceramic fabricators to enable further technology developments in the ceramics industry.
The manufacturing will first be applied to the energy market, but has the potential to impact defense and health imaging technologies as well.
This Small Business Innovation Research (SBIR) Phase I project seeks to scale the throughput capacity of a dry-powder pressing additive manufacturing technique that can fabricate multifunctional ceramic monoliths with internal flow structures.
Five key capabilities distinguish dry-powder pressing additive manufacturing from existing ceramic additive manufacturing methods:
I) Applicability to materials not amenable to laser sintering,
II) Co-deposition of multiple materials with high lateral precision,
III) Densification of materials typically incapable of pressureless sintering to full density,
IV) A quality control step can reject a layer prior to adhering to prior layers, and
V) Co-deposition of fugitive material can form internal gas routing that eliminates costly and complex ceramic sealing technology in harsh environment applications.
The proposed work will advance the technology by creating a high-throughput printing system to deposit patterned 50 cm² layers in a single pass, representing a 100x throughput increase.
Automation will also address two precision targets; layer deposition below 7.5 mg/cm² and lateral resolution less than 0.5 mm.
The scope of work will advance the science of dry powder deposition and transfer to refine the processing capability for thinner layers and finer microfeatures while simultaneously engineering a high throughput device representative of pilot-scale manufacturing.
This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the foundation's intellectual merit and broader impacts review criteria.
Subawards are not planned for this award.
Awardee
Funding Goals
THE GOAL OF THIS FUNDING OPPORTUNITY, "NSF SMALL BUSINESS INNOVATION RESEARCH (SBIR)/ SMALL BUSINESS TECHNOLOGY TRANSFER (STTR) PROGRAMS PHASE I", IS IDENTIFIED IN THE LINK: HTTPS://WWW.NSF.GOV/PUBLICATIONS/PUB_SUMM.JSP?ODS_KEY=NSF23515
Grant Program (CFDA)
Awarding / Funding Agency
Place of Performance
Pullman,
Washington
99163-5409
United States
Geographic Scope
Single Zip Code
Alternative Energy Materials was awarded
Project Grant 2419486
worth $274,915
from National Science Foundation in December 2024 with work to be completed primarily in Pullman Washington United States.
The grant
has a duration of 1 year and
was awarded through assistance program 47.084 NSF Technology, Innovation, and Partnerships.
The Project Grant was awarded through grant opportunity NSF Small Business Innovation Research / Small Business Technology Transfer Phase I Programs.
SBIR Details
Research Type
SBIR Phase I
Title
SBIR Phase I: Dry Powder Pressing Additive Manufacturing (DPP-AM)
Abstract
The broader/commercial impact of this Small Business Innovation Research (SBIR) Phase I project will be the development of a new additive manufacturing technique for ceramic materials. Technical ceramics provide unmatched performance in harsh environment applications found throughout the energy, defense, healthcare, and IT sectors. Applications requiring miniaturization or process intensification would benefit from a novel additive ceramic manufacturing that can form internal microfeatures and combine different materials into functional layers for chemical reactions, imaging, or energy transfer. This proposal will advance from proof-of-concept to a functional prototype of a dry powder pressing additive manufacturing printer. This work will improve our understanding of the fluidization and aerosolization of ultrafine and dense nanopwders that are prone to compaction and static adhesion. The high-resolution from dry powder pressing additive manufacturing will lower monolith fabrication cost an order of magnitude to accelerate the adoption of emerging ceramic technologies. No existing ceramic production technology can combine multiple functional materials in the same layer or produce internal flow features at the proposed sub-mm scale. The technology will be leased or sold to advanced ceramic fabricators to enable further technology developments in the ceramics industry. The manufacturing will first be applied to the energy market, but has the potential to impact defense and health imaging technologies as well.
This Small Business Innovation Research (SBIR) Phase I project seeks to scale the throughput capacity of a dry-powder pressing additive manufacturing technique that can fabricate multifunctional ceramic monoliths with internal flow structures. Five key capabilities distinguish dry-powder pressing additive manufacturing from existing ceramic additive manufacturing methods: i) applicability to materials not amenable to laser sintering, ii) co-deposition of multiple materials with high lateral precision, iii) densification of materials typically incapable of pressureless sintering to full density, iv) a quality control step can reject a layer prior to adhering to prior layers, and v) co-deposition of fugitive material can form internal gas routing that eliminates costly and complex ceramic sealing technology in harsh environment applications. The proposed work will advance the technology by creating a high-throughput printing system to deposit patterned 50 cm2 layers in a single pass, representing a 100x throughput increase. Automation will also address two precision targets; layer deposition below 7.5mg/cm2 and lateral resolution less than 0.5mm. The scope of work will advance the science of dry powder deposition and transfer to refine the processing capability for thinner layers and finer microfeatures while simultaneously engineering a high throughput device representative of pilot-scale manufacturing.
This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.
Topic Code
AM
Solicitation Number
NSF 23-515
Status
(Ongoing)
Last Modified 8/27/24
Period of Performance
12/1/24
Start Date
11/30/25
End Date
Funding Split
$274.9K
Federal Obligation
$0.0
Non-Federal Obligation
$274.9K
Total Obligated
Activity Timeline
Additional Detail
Award ID FAIN
2419486
SAI Number
None
Award ID URI
SAI EXEMPT
Awardee Classifications
Small Business
Awarding Office
491503 TRANSLATIONAL IMPACTS
Funding Office
491503 TRANSLATIONAL IMPACTS
Awardee UEI
VHFDSRYADLQ2
Awardee CAGE
9HAJ4
Performance District
WA-05
Senators
Maria Cantwell
Patty Murray
Patty Murray
Modified: 8/27/24