National Technology & Engineering Solutions of Sandia, LLC

Other

Sandia Corporation

Duracell U.S. Operations, Inc.

Adam W Cook

Bryan James Kaehr

David Michael Keicher

Paul Gilbert Clem

Mathias C Celina

Leah N Appelhans

Michael Pozin

Clifford Kuofei Ho

Marcelino Essien

Michael Hibbs

Walter Fred Paxton

Valerie J Heilbron

Susan J Altman

Samuel Leguizamon

Ethan Benjamin Secor

Brad Howard Jones

William Reinholtz

Devin J Roach

Carl Erik Linde

Rebecca Rosa Tafoya

Eloy Phillip Baldonado

Kylie Manning

Aerosol jet printing is a popular digital fabrication method for flexible and hybrid electronics, but it lacks sophisticated process control architectures that would enable more widespread adoption in manufacturing environments. An optical measurement system can be used to track the aerosol density upstream of the printhead. For example, the measured optical extinction combined with the aerosol flow rate, is directly related to deposition rate and accurately predicts functional properties, for example electrical resistance. This real-time system offers a compelling solution for process drift and batch-to-batch variability, a valuable tool for more fundamental studies of the process science, and a viable technology to support real-time control of aerosol jet printing.

Optical measurement system for real-time process monitoring of aerosol jet printing

The invention is directed to latent metathesis-active resin compositions and additive manufacturing approaches. The latent metathesis-active compositions comprise at least one latent metathesis catalyst, at least one curable metathesis-active monomer, and optional fillers, photosensitizers, and/or a secondary monomer resin system for dual-cure. A method comprises extruding a latent metathesis-active resin from a dispensing apparatus and spatially triggering a ring-opening metathesis polymerization by directed irradiation with light or directed application of a thermal stimuli for direct-ink write printing of objects. Another method uses a latent metathesis-active resin for vat photopolymerization and stereolithographic printing of objects.

Use of latent metathesis polymerization systems for additive manufacturing

Direct ink write (DIW) printing of reactive resins presents a unique challenge due to the time-dependent nature of the rheological and chemical properties of the ink. As a result, careful print optimization or process control is important to obtain consistent, high quality prints. The present invention uses a flow-through characterization cell for in situ chemical monitoring of a resin ink during DIW printing. Additionally, in-line extrusion force monitoring can be combined with off-line post inspection using machine vision. By combining in-line spectroscopy and force monitoring, it is possible to follow reaction kinetics (for example, curing of a reactive resin) and viscosity changes during printing, which can be used for a closed-loop process control. Additionally, the capability of machine vision to automatically identify and quantify print artifacts can be incorporated on the printing line to enable real-time, AI-assisted quality control of the printed products. Together, these techniques can form the building blocks of an optimized process control strategy when complex reactive ink must be used to produce printed hardware.

Real-time process monitoring for direct ink write additive manufacturing

The present invention relates to formulations including a self-assembly monomer. In particular embodiments, the self-assembly monomer provides a thermoset having beneficial viscoelastic properties for printing methodologies. Methods of making and using such formulations are also provided.

Self-assembly assisted additive manufacturing of thermosets

The present invention relates, in part, to methods of preparing a safety battery. Methods can include dispensing a safety ink formulation between the two poles of a battery. Upon exposure to moisture, the formulation provides an electrical connection between two poles, thus minimizing electrical discharge and/or reducing the formation of electrochemically generated ions at the pole(s).

Methods of preparing a safety battery

Hydrodynamic focusing of two fluid steams provides a novel micro printing technology for printed electronics and other high performance applications.

Two-fluid hydrodynamic printing

The invention provides pneumatic shuttering of a focused or collimated aerosol particle stream. The aerosol stream can be collimated by an annular sheath of inert or non-inert gas. The apparatus propagates a sheathed aerosol stream through a series of aerodynamic lenses along the axis of a flow cell. The final lens is typically positioned above a substrate, so that direct material deposition is provided. A substantially perpendicularly-flowing gas external to the aerodynamic lens system is used to redirect the particle stream away from the flow axis and through an exhaust port, thereby shuttering the collimated aerosol stream. The pneumatic shutter enables printing of discreet structures, with on/off shuttering times of approximately 1 to 100 milliseconds.

Apparatus for pneumatic shuttering of an aerosol particle stream

An illuminated display device with a base member with a plurality of cavities therein. Illumination devices illuminate the cavities and emit light through an opening of the cavities in a pattern, and a speaker can emit sounds in synchronization with the pattern. A panel with translucent portions can overly the base member and the cavities. An animated talking character can have an animated mouth cavity complex with multiple predetermined mouth lighting configurations simulative of human utterances. The cavities can be open, or optical waveguide material or positive members can be disposed therein. Reflective material can enhance internal reflectance and light emission.

Lighted display devices for producing static or animated visual displays, including animated facial features

An array of airfoil-shaped micro-mixers that enhances fluid mixing within permeable membrane channels, such as used in reverse-osmosis filtration units, while minimizing additional pressure drop. The enhanced mixing reduces fouling of the membrane surfaces. The airfoil-shaped micro-mixer can also be coated with or comprised of biofouling-resistant (biocidal/germicidal) ingredients.

Growing community of inventors

Albuquerque, NM, United States of America

Adam W Cook