Engineering topics

Oakdale, James

Publications and source records attributed to Oakdale, James.

7 records

DOE OSTI2024

Additive manufacturing of hierarchical three- dimensional micro-architected aerogels

Disclosed here is a method for making a three-dimensional micro-architected aerogel, comprising: (a) curing a reaction mixture comprising a co-sol-gel material (e.g., graphene oxide (GO)) and at least one catalyst to obtain a crosslinked co-sol-gel (e.g., GO hydrogel); (b) providing a photoresin comprising a solvent, a photoinitiator, a crosslinkable polymer precursor, and a dispersion of the crosslinked co-sol-gel (e.g., GO hydrogel); (c) curing the photoresin using projection microstereolithography layer-by-layer to produce a wet gel having a pre-designed three-dimensional structure; (d) drying the wet gel to produce a dry gel; and (e) pyrolyzing the dry gel to produce a three-dimensional micro-architected aerogel (e.g., graphene aerogel). Also disclosed is a photoresin for projection microstereolithography, comprising a solvent, a photoinitiator, a crosslinkable polymer precursor, and a dispersion of a crosslinked co-sol-gel.

Worsley, Marcus A.↗

DOE OSTI2023

Photocurable resins for volumetric additive manufacturing

Methods and materials for volumetric additive manufacturing, including computed axial lithography (“CAL”), using photosensitive resins comprising a photocurable resin prepolymer; a photoinitiator; and (optionally) a curing inhibitor. In various embodiments, such photosensitive polymers comprise (a) one or more monomer (or prepolymer) molecules, which form the backbone of the polymer network of the polymeric material and define its architecture; and (b) a photoinitiator that captures illumination energy and initiates polymerization.

Shusteff, Maxim↗

DOE OSTI2023

System and method for roll-to-roll film tensioning for reduced separation force during bottom-up stereolithography

The present disclosure relates to a tensioning system for use in a stereolithography manufacturing application. The system may have a build plate for supporting a three dimensional part being formed using a photo responsive resin, a base plate and a release element extending over the base plate. The release element is configured to receive a quantity of photo responsive resin for forming a new material layer of the three dimensional part. A pair of tensioning components are secured to opposite ends of the release element, and apply a controlled tension force to the release element during peeling of the release element to reduce a separation force required to separate the release element from the new material layer after the new material layer is cured.

Duoss, Eric B.↗

DOE OSTI2021

Ultra-low-density digitally architected carbon with a strutted tube-in-tube structure

Porous materials with engineered stretching-dominated lattice designs, which offer attractive mechanical properties with ultra-light weight and large surface area for wide-ranging applications, have recently achieved near-ideal linear scaling between stiffness and density. Here, rather than optimizing the microlattice topology, we explore a different approach to strengthen low-density structural materials by designing tube-in-tube beam structures. We develop a process to transform fully dense, three-dimensional printed polymeric beams into graphitic carbon hollow tube-in-tube sandwich morphologies, where, similar to grass stems, the inner and outer tubes are connected through a network of struts. Compression tests and computational modelling show that this change in beam morphology dramatically slows down the decrease in stiffness with decreasing density. In situ pillar compression experiments further demonstrate large deformation recovery after 30–50% compression and high specific damping merit index. Lastly, our strutted tube-in-tube design opens up the space and realizes highly desirable high modulus–low density and high modulus–high damping material structures.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Dynamic Polymer Networks for On Demand Degradable Adhesives, Scaffolds, and Templates (Full Technical Report)

This feasibility study was motivated by a need for alternative mandrel materials to meet the next generation of inertial confinement fusion (ICF) ablator capsules. In response, a new polymer material based on reversible covalent bonds was proposed, with the objective to design thermosets to withstand elevated temperatures (140-200 degrees Celsius) while also being thermally degradable on-demand via controlled decomposition at temperatures above 200 degrees Celsius. A series of cyclopentadiene (Cp) containing thermosets were designed and synthesized to evaluate curing, reversibility and degradability via controlled retro-Diels Alder reactions using Cp-cycloaddition adducts as crosslinks. Ultimately, the current iteration of materials and strategy pursued in this study was assessed as impractical for meeting the needs and objectives of Lawrence Livermore National Laboratory’s (LLNL) target fabrication program.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Dynamic Networks for On Demand Degradable Adhesives, Scaffolds and Templates (Abbreviated Final Report)

This feasibility study was motivated by a need for alternative mandrel materials to meet the next generation of inertial confinement fusion (ICF) ablator capsules. In response, a new polymer material based on reversible covalent bonds was proposed, with the objective to design thermosets to withstand elevated temperatures (140-200 degrees Celsius) while also being thermally degradable on-demand via controlled decomposition at temperatures above 200 degrees Celsius. A series of cyclopentadiene (Cp) containing thermosets were designed and synthesized to evaluate curing, reversibility and degradability controlled via retro-Diels Alder reactions using Cp-cycloaddition adducts as crosslinks. Ultimately, the current iteration of materials and strategy pursued in this study was assessed as impractical for meeting the needs and objectives of Lawrence Livermore National Laboratory’s (LLNL) target fabrication program.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Three-dimensional deterministic graphene architectures formed using three-dimensional templates

In one embodiment, a composition of matter includes: a plurality of ligaments each independently comprising one or more layers of graphene; where the plurality of ligaments are arranged according to a deterministic three-dimensional (3D) pattern. In another embodiment, a method of forming a deterministic three-dimensional (3D) architecture of graphene includes: forming or providing a substrate structurally characterized by a predefined 3D pattern; forming one or more layers of metal on surfaces of the substrate; and forming one or more layers of graphene on surfaces of the metal.

36 MATERIALS SCIENCE↗