ACTUATED MEDICAL, INC. — National Aeronautics and Space Administration SBIR Phase I: H7

Description

<p style="margin-left:0in; margin-right:0in">There is a significant gap between the properties of materials that are produced using the current 3D printing processes and the properties that are needed to support critical space systems.&nbsp; The polyetherimide/polycarbonate (PEI/PC) composite recently demonstrated on the ISS is a significant step forward in development, however, FDM with PEI/PC represents the current practical limits of AM in space due to the temperature requirements to produce other materials</p><p style="margin-left:0in; margin-right:0in">In this Phase I SBIR,<strong> </strong>AMI, an ISO 13485-Certified (FDA GMP Compliant) Medical Device Developer and Manufacturer, will partner with PSU professors Dr. Michael Hickner of the Center for Innovative Materials Processing through Direct Digital Deposition (CIMP-3D) and Dr. Benjamin Lear, Associate Professor of Chemistry to develop, test, and commercialize a carbon fiber reinforced (CFR) PEEK composite feedstock with improved deposition and strength through focused photothermal polymerization. &nbsp;Polymics Inc, a local company with expertise in compounding PEEK, will produce feedstock ready for 3D print.&nbsp; The project proposed combines three complimentary approaches to achieve additive manufacturing of precision parts with CFR PEEK:</p><ol><li>Formulation addition of carbon microfibers to PEEK filament feedstock to increase overall strength.</li><li>Modification of carbon microfibers by impregnating/coating gold nanoparticles to enable photothermally-enhanced bonding to the previous layer.</li><li>Incorporation of a focused laser beam adjacent to the print head to initiate localized photothermal heating and localized additional heating directly at the extrusion exit point.</li> </ol>