This Project Grant award from the National Science Foundation's Engineering program (CFDA 47.041) supports research to develop a novel additive manufacturing process called Vacancy-Assisted Jet Fusion (VJF) for fabricating complex parts from transition-metal-carbide (TMC) ceramics. The $300,000 award to the University of Iowa aims to (1) quantify the effects of layerwise triggered electron flow on the diffusion of locally induced crystal vacancies, (2) uncover the underlying mechanisms governing...
This $314,721 federal Project Grant awarded by the National Science Foundation (NSF) Engineering Program (CFDA 47.041) supports research to develop durable, 3D-printable ceramic nanocomposite materials. The University of Illinois, as the prime awardee, will explore using small quantities of boron nitride nanotubes to enhance the fracture toughness and reliability of polymer-derived ceramic materials, which are compatible with 3D printing but prone to fracture. Through complementary multiscale...
This $155,000 Project Grant from the National Science Foundation (NSF) Office of Integrative Activities (CFDA 47.083) supports fundamental research at Iowa State University to understand how nanoparticle self-assembly can be integrated into laser/powder-based additive manufacturing (AM) of multimodal metallic materials. The overall goal is to gain a deeper understanding of the mechanisms governing nanoparticle self-assembly behavior, microstructure evolution, and property enhancements in AM of...
This $800,000 Project Grant awarded by the National Science Foundation's (NSF) Mathematical and Physical Sciences program (CFDA 47.049) will enable Iowa State University of Science and Technology to develop new materials and manufacturing methods for 3D printing multi-material objects with varying mechanical properties. The key objectives are to use machine learning to create resins enabling extreme mechanical contrast, develop a multi-material 3D printing process using photoswitches, and...
The National Science Foundation (NSF) awarded a $453,682 Faculty Early Career Development (CAREER) grant to Arizona State University (ASU) to conduct fundamental research on ceramic binder jet additive manufacturing. The project, titled "CAREER: Powder Preparation and Compaction for Ceramic Binder Jet Additive Manufacturing," aims to generate new knowledge about how powder granule characteristics and compaction affect the density of ceramic parts produced through this advanced...
This Project Grant from the National Science Foundation's Division of Civil, Mechanical, and Manufacturing Innovation, under the Engineering program (CFDA 47.041), provides $481,998 to support research at the University of California, Berkeley on developing a new additive manufacturing process for multi-material and multi-functional part fabrication. The principal investigator will conduct fundamental research into a charge-programmed additive microfabrication technique to rapidly pattern...
This federal Project Grant award from the National Science Foundation's Engineering program (CFDA 47.041) provides $335,000 to The Research Foundation for the State University of New York to conduct collaborative research on developing tough and 3D-printable ceramic nanocomposites. The research aims to overcome the intrinsic fragility of ceramic materials by introducing small quantities of boron nitride nanotubes into polymer-derived ceramics. This work will enable the development of...
This Project Grant award of $599,342 from the National Science Foundation's Engineering program (CFDA 47.041) supports fundamental research to understand the processing mechanisms of a novel additive manufacturing (AM) approach for high-performance tungsten alloy fabrications. The research aims to advance innovations in next-generation, scalable AM processes for refractory alloy manufacturing through compression-enabled filament-extrusion AM, binder removal, and hybrid-phase sintering. Key...
This Project Grant award from the National Science Foundation Office of Integrative Activities (CFDA 47.083) will support research at Iowa State University on the development, characterization, and performance evaluation of surface engineered additively manufactured parts for nuclear reactor applications. Specifically, the university will utilize a laser-based directed energy deposition process to fabricate metallic parts from Nitronic 60 stainless steel, a material used in nuclear reactor...
The National Science Foundation awarded a $567,121 Project Grant to Michigan State University under the Engineering (47.041) federal grant program. The grant funds fundamental research to develop a new metal additive manufacturing process using light projection of mixtures of photopolymer and metal powder. Rather than point-by-point printing, the proposed process would use digital light projection to cure an entire layer of photopolymer mixed with metal powder. This could enable high-speed...
This $603,512 National Science Foundation project grant supports the development of novel additive manufacturing techniques for complex structural ceramics. Funded under the Engineering program (CFDA 47.041), the five-year award to the University of Iowa aims to mature a powder bed ceramic additive manufacturing process assisted by water-based inks, layerwise uniaxial compression, and temperate heating for selective particle fusion.
By employing selectively deposited water-based inks followed by layer-by-layer uniaxial compression and mild heating, the project seeks to enable the manufacture of complex thick-walled ceramic components without the need for binder removal. Instrumented compression testing, multi-scale characterization, and pore-scale simulations will elucidate the effects of processing conditions and material properties on particle fusion mechanisms and density. Findings are expected to uncover the governing mechanisms for neck formation between ceramic particles and identify factors determining fusion strength. This will ultimately enable complex ceramic components with minimal defects, full density, and enhanced properties.