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Results for “Digital Fabrication”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Digital fabrication of a small diameter polymer optical waveguide

A novel polymer optical waveguide and method of manufacturing is presented herein. A digitally manufactured process is described which utilizes a micro-dispensed UV optical adhesive as the contour guiding cladding, a fused deposition modeling technology for creating a core, and a subtractive laser process to finish the two ends of the optical interconnect. The optical waveguide can be printed directly on a circuit board in some embodiments. Alternatively, using a slightly modified process including a step to bond the optical fiber to the substrate, the optical interconnect can be manufactured on a flexible substrate.

Bhethanabotla, Venkat Rama↗
DOE OSTI2020

Atomically precise digital e-beam lithography

Hydrogen Depassivation Lithography (HDL) is a version of electron beam lithography that uses scanning tunneling microscope (STM) instrumentation to expose a self–developing resist that is a monolayer of H chemisorbed to a Si (100) 2x1 H-passivated surface. Developed in the 1990s it has been largely a laboratory tool used in research for nanofabrication. Here, the technique is capable of atomic resolution, the ability to remove single H atoms from the Si surface and has much higher precision than the best conventional e-beam lithography can possibly achieve exposing polymeric resists. However, its most promising attribute is that it can be used as a digital fabrication tool and is the first of a class of nanofabrication techniques that can be considered digital atomic scale fabrication technologies. Digital Atomic Scale Fabrication can be shown to have similar advantages over analog fabrication techniques that digital information technology has over analog information technology.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2023

Fulcrum House – Towards a Sustainable Composite Architecture

In the last decades, the accessibility to digital fabrication technologies positioned composites as an affordable, structurally efficient and low-maintenance alternative to traditional mineral-based and high-energy materials. Of special interest are carbon nanotubes (CNT) and carbon foam (CFoam) from methane and coal pyrolysis respectively, as an environmentally friendly substitute to glass and carbon fiber. This paper presents the design of a principled single-family house, as a first case study to identify the constraints of such a material system, including technology gap, techno-economic and life cycle assessment, as well as building code requirements. In turn, the investigation proposes a suitable design-to-fabrication workflow, which potentially could bring CNT and CFoam materials to the construction of buildings.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Printed hygroscopic electrodes for low-cost capacitive relative humidity sensors

A capacitive relative humidity sensor includes a first electrode and a second electrode, where at least the one of the electrodes is a water-permeable electrode. The electrodes act in conjunction with a water-sensitive hygroscopic dielectric material. The design enables low-cost and simple fabrication of fast-responding and stable relative humidity sensors using digital fabrication techniques.

Pierre, Adrien↗
DOE OSTI2022

Review of Computer-Aided Manufacturing (CAM) strategies for hybrid directed energy deposition

Hybrid additive manufacturing intertwines both additive and subtractive manufacturing layer by layer to digitally fabricate parts with complex geometries, improved surface finish and tight dimensional accuracies, the sum of which is difficult to obtain with any single process. Computer-Aided Manufacturing (CAM) software is required to orchestrate the machine toolpathing for both the deposition as well as the machining processes and is crucial for the successful fabrication of high quality structures. Additionally, CAM requires substantial operator input to account for challenging aspects of each fabricated structure. For example, deciding at which layer of deposition will the machining process continue to maintain access to complex cavities for finishing - internal features that would otherwise be unfinishable due to reach limitations or obstructions. Moreover, of the many commercially-available hybrid systems, each has a unique kinematic environment which can benefit from specific optimization of toolpath planning and substantial research has directly correlated toolpathing with the microstructure evolution, mechanical properties, porosity and residual stress state of the final fabricated part. This review explores the available strategies for CAM in the context of hybrid direct energy deposition, discusses the advantages and disadvantages of each and considers future CAM trends for this transformational digital manufacturing technology.

36 MATERIALS SCIENCE↗
DOE OSTI2023

The Effect of Laser Cutting Heuristic Presentation Modality on Design Learning

Abstract The goal of this work is to study the way student designers use heuristics to effectively design for laser-cut manufacturing methods. With the recent advent of academic makerspaces, digital fabrication tools like laser cutters are relatively new additions to the classroom. Therefore, there is a gap in formal education or training on these tools, and students can find it challenging to design effectively for them. A study was performed to investigate the way students apply heuristics to redesign laser-cut assemblies when received in different modalities. All participants were given an identical lecture on laser cutting heuristics. Then, a redesign problem was presented to students, and three different experimental groups were given the heuristics in different modalities: Text-Only, text with Visual aids, and text with Tactile aids. The novelty and quality of each of the resulting redesigns were evaluated. It was hypothesized that participants would have more difficulty interpreting and applying the Text-Only heuristics, lowering the quality of their redesigned solutions relative to the other two conditions. It was also hypothesized that participants would experience fixation caused by interacting with the tactile aids, leading to the lower novelty of their redesigned solutions relative to the other two conditions. Results showed that modality played a significant role in participants’ feelings of self-efficacy after the intervention, as well as in their understanding of laser cutter design skills when responding to quiz-style questions. However, analysis of novelty and quality showed little significant impact of the intervention and varying modalities on participants’ designs.

Engineering↗
DOE OSTI2023

Using micro-XRF to characterize chloride ingress through cold joints in 3D printed concrete

Digital fabrication methods with concrete have been rapidly developing, with many problems related to component production and material control being solved in recent years. These processes produce inherently layered cementitious components that are anisotropic, and in many cases, produces a weak interface between layers, which are generally referred to as cold joints. While material strength at these interfaces has been well studied in recent years, durability has received less attention, even though cold joints can function as channels for aggressive agents, such as chlorides. This work presents a method using micro-X-ray fluorescence (μXRF) to image chloride ingress into layer interfaces of 3D printed fine-grained concrete specimens produced with varying layer deposition time intervals, and also compares it to neutron imaging of moisture uptake. The results show that cold joints formed after a 1 day time interval are highly susceptible to chloride ingress, and that curing conditions play a major role in how quickly interfacial transport can take place. The μXRF method is also shown to be useful for study of transport of chlorides in cold joints, due to its spatial resolution and direct analysis of an aggressive species of interest.

36 MATERIALS SCIENCE↗
DOE OSTI2023

1. Introduction to Additive Manufacturing

Additive manufacturing (AM) is the process of constructing an object by adding layer upon layer of material in specific locations, to build the object into its final shape. There are many different AM processes that can be used to add layers of material, such as extrusion, material jetting, and sheet lamination. All of the AM processes are a form of digital fabrication because the object to be constructed must first be modeled with a computer. The modeled object must be converted into machine instructions that an AM system can use to construct the object. This chapter serves as an introduction to the many different AM processes. Subsequent chapters will explore the intricacies of creating machine instructions for the AM processes introduced here.

Macdonald, Eric↗
DOE OSTI2020

Horizons of modern molecular dynamics simulation in digitalized solid freeform fabrication with advanced materials

Our ability to shape and finish a component by combined methods of fabrication including (but not limited to) subtractive, additive and/or no theoretical mass-loss/addition during the fabrication is now popularly known as solid free form fabrication. Fabrication of a telescope mirror is a typical example where grinding and polishing processes are first applied to shape the mirror and thereafter an optical coating is usually applied to enhance its optical performance. The area of nanomanufacturing cannot grow without a deep knowledge of the fundamentals of materials and consequently, the use of computer simulations is becoming ubiquitous. This article is intended to introduce the most recent advances in the computation benefit specific to the area of solid free form fabrication as these systems are traversing through the journey of digitalisation and Industry-4.0. Specifically, this article demonstrates that the application of the latest materials modelling approaches, based on techniques such as molecular dynamics, are enabling breakthroughs in applied precision manufacturing techniques.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Physics augmented machine learning discovery of composition-dependent constitutive laws for 3D printed digital materials

Multi-material 3D printing, particularly through polymer jetting, enables the fabrication of digital materials by mixing distinct photopolymers at the micron scale within a single build to create a composite with tunable mechanical properties. Here, this work presents an integrated experimental and computational investigation into the composition-dependent mechanical behavior of 3D printed digital materials. We experimentally characterize five formulations, combining soft and rigid UV-cured polymers under uniaxial tension and torsion across three strain and twist rates. The results reveal nonlinear and rate-dependent responses that strongly depend on composition. To model this behavior, we develop a physics-augmented neural network (PANN) that combines a partially input convex neural network (pICNN) for learning the composition-dependent hyperelastic strain energy function with a quasi-linear viscoelastic (QLV) formulation for time-dependent response. The pICNN ensures convexity with respect to strain invariants while allowing non-convex dependence on composition. To enhance interpretability, we apply $L_0$ sparsification. For the time-dependent response, we introduce a multilayer perceptron (MLP) to predict viscoelastic relaxation parameters from composition. The proposed model accurately captures the nonlinear, rate-dependent behavior of 3D printed digital materials in both uniaxial tension and torsion, achieving high predictive accuracy for interpolated material compositions. This approach provides a scalable framework for automated, composition-aware constitutive model discovery for multi-material 3D printing.

Constitutive modeling↗
DOE OSTI2026

Smaller feature size impairs densification in digital light processing 3D printed ceramic samples

In this study, we investigate how geometric miniaturization affects the sintering densification behavior of alumina cylinders with various wall thicknesses (down to ∼500 µm in green body) fabricated via digital light processing (DLP). As the wall thickness decreased, the density of the sintered samples consistently declined. Microstructural characterization revealed the presence of a crack-rich surface skin that is ∼500 µm thick. As the wall thickness decreases, the skin's volume fraction rises, and its poor local densification increasingly dominates the part average, leading to an overall decrease in the density of the sintered samples. For the thinnest wall (500 µm) cylinder, macroscopic warping occurred during sintering. We suggest that warping further disrupts particle packing and induces through-thickness nonuniformity, further impairing densification in addition to the skin-fraction effect. These results highlight how geometric miniaturization may adversely influence the sintering behavior and final density of DLP-printed ceramics through distinct densification-limiting mechanisms.

Materials science↗
DOE OSTI2021

A Comparative Study of Direct and Indirect Additive Manufacturing Approaches for the Production of a Wind Energy Component

Additive manufacturing (AM) was developed in the 1980s to create three-dimensional prototypes through layer-wise approaches to fabrication. Since then, these approaches have seen improvements in both materials and processing technologies. To date, there are now 7 types of additive manufacturing processes and hundreds of materials, which can be directly printed – going directly from digital design to fabricated components. In this project, Oak Ridge National Laboratory (ORNL), Vestas Wind Systems, and The National Renewable Energy Laboratory (NREL) collaborated to evaluate the effectiveness of state-of-the-art large-scale AM processes in the production of a structural component for use in a wind turbine nacelle, through both direct and indirect manufacturing approaches. Here, experienced AM design engineers detail techniques for AM design, including topology optimization (TO), support minimization, reverse engineering, and techniques for mitigating poor interlaminar performance. Fabrication of the components is presented, including printing parameters and postprocessing, and followed with full-scale component testing by a 3rd party testing laboratory. To evaluate the potential of the developed approaches, a complete techno-economic analysis is provided which evaluates the cost of these techniques given current and near to long-term projections of AM system capabilities.

17 WIND ENERGY↗
DOE OSTI2022

GaN HEMT Fabrication for Radiation-Hardened Sensing and Communications Electronics

Gallium nitride (GaN), a wide bandgap semiconductor, has vast potential to address two environment conditions associated with the application of electronics to nuclear power: elevated temperatures, and high levels of radiation. A process was developed at The Ohio State University (OSU) to enable fabrication of complex digital and analog electronics circuits for application to nuclear power environments such as locations near or in the reactor core or in spent nuclear fuel casks. Radio frequency (RF)-grade GaN high electron mobility transistor (HEMT) devices were fabricated as part of this process. These were fabricated as depletion mode and enhancement mode devices. They have been electrically characterized and have demonstrated the expected performance. Behavioral models (Verilog-A) were developed from these device measurements to enable electrical simulation of GaN HEMT devices and circuits using common electronics simulation tools based on Simulation Program with Integrated Circuit Emphasis (SPICE). A similar set of GaN HEMT devices is being developed to provide lower speed devices for logic and analog functions. These accomplishments position this technology for effective application to sensor interfacing, signal processing, and data communications in nuclear power plants, including operation in or near the reactor core.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Hybrid Additive Manufacturing and Electric Field-Assisted Sintering of High-temperature Heat Exchangers via Sacrificial Channel Molds

A hybrid manufacturing approach, integrating additive manufacturing (AM) with powder methodology via electric field-assisted sintering (EFAS), was developed for the fabrication of high-temperature compact heat exchangers (CHX) from refractory metals. The methodology employed additively manufactured sacrificial channel molds (SCMs) as shapeholders for CHX channels, which were embedded in metal powders using EFAS. Following embedding, the SCMs were chemically dissolved to form the internal channel network. SCMs were fabricated using both digital light processing (DLP) and direct ink writing (DIW) from chemically reactive, calcium-based ceramic feedstocks with varying ratios of Al2O3 reinforcement. The microstructure, phase composition, and dissolution behavior of both as-printed and embedded SCMs were investigated. The shrinkage behavior of the SCMs embedded in refractory metals, as well as the interfacial characteristics between the SCMs and metal matrix, were studied. The results showed that the SCMs containing sufficient chemical reactive ceramics dissolved effectively before and after embedding. The as-printed SCMs retained the phase composition of their feedstocks, but the embedded SCMs containing calcium-based ceramics and Al2O3 exhibited the formation of calcium aluminates due to high temperature exposure during embedding. Most SCMs exhibited a cellular Al2O3 network filled with Ca-rich ceramics. Shrinkage after embedding was strongly dependent on SCM density, with lower density SCMs exhibiting greater shrinkage. A thin SCM-affected zone was observed at the metal matrix surface, characterized by increased porosity compared to the bulk matrix. This effect was attributed to infiltration of the SCM materials into powder particle boundaries under pressure, followed by their removal during dissolution. This study demonstrates the feasibility of manufacturing CHXs from hard-to-process refractory metals for use in harsh environments.

36 - MATERIALS SCIENCE↗