Sandia Corporation

National Technology & Engineering Solutions of Sandia, LLC

Mathias C Celina

Adam W Cook

C Garrett Campbell

Steven G Thoma

Erik David Spoerke

Mark R Vaughn

Mark C Grubelich

Stephen John Percival

Leah N Appelhans

Eric John Schindelholz

Steven D Knudsen

Nicholas Henry Giron

Devin J Roach

Kylie Manning

Carl Erik Linde

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

Nanocomposite anticorrosion coating can be achieved by depositing alternating, multilayers of a cross-linkable polymer and dispersed and aligned inorganic platelets followed by cross-linking of the cross-linkable polymer. The cross-linkable polymer can be an externally cross-linkable polymer that is cross-linked by diffusing a cross-linking agent into the deposited multilayer coating. Alternately, the cross-linkable polymer can be a functionalized cross-linkable polymer that is cross-linked by self-curing, thermal heat curing, or light (e.g., UV) following deposition of the multilayer coating.

Cross-linkable nanocomposite anticorrosion coating

The invention is directed to a method of controlled conversion of thermosetting resins and additive manufacturing thereof by selective laser sintering. Partial curing of a thermosetting formulation can be used to increase the Tof the resin and minimize the additional cure needed to cross-link a printed object. After printing, the partially cured material is finally cured via a slow temperature ramp maintained just below the material's evolving T.

Method of controlled conversion of thermosetting resins and additive manufacturing thereof by selective laser sintering

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

A self-consuming structure is disclosed that is formed from a self-consuming composition based on an epoxy or polyurethane having fuel and/or oxidizer molecularly dispersed and/or as particulates in the epoxy or polyurethane. The composition may be used to form self-consuming structural components.

Self-consuming materials

A cyanate ester resin mixture with at least one cyanate ester resin, an isocyanate foaming resin, other co-curatives such as polyol or epoxy compounds, a surfactant, and a catalyst/water can react to form a foaming resin that can be cured at a temperature greater than 50&#xb0; C. to form a cyanate ester foam. The cyanate ester foam can be heated to a temperature greater than 400&#xb0; C. in a non-oxidative atmosphere to provide a carbonaceous char foam.

Method of making a cyanate ester foam

An epoxy resin mixture with at least one epoxy resin of between approximately 50 wt % and 100 wt %, an anhydride cure agent of between approximately 0 wt % and approximately 50 wt %, a tert-butoxycarbonyl anhydride foaming agent of between proximately 0.1-20 wt %, a surfactant and an imidazole or similar catalyst of less than approximately 2 wt %, where the resin mixture is formed from at least one epoxy resin with a 1-10 wt % tert-butoxycarbonyl anhydride compound and an imidazole catalyst at a temperature sufficient to keep the resin in a suitable viscosity range, the resin mixture reacting to form a foaming resin which in the presence of an epoxy curative can then be cured at a temperature greater than 50&#xb0; C. to form an epoxy foam.

Method for epoxy foam production using a liquid anhydride

An epoxy resin mixture with at least one epoxy resin of between approximately 60 wt % and 90 wt %, a maleic anhydride of between approximately 1 wt % and approximately 30 wt %, and an imidazole catalyst of less than approximately 2 wt % where the resin mixture is formed from at least one epoxy resin with a 1-30 wt % maleic anhydride compound and an imidazole catalyst at a temperature sufficient to keep the maleic anhydride compound molten, the resin mixture reacting to form a foaming resin which can then be cured at a temperature greater than 50&#xb0; C. to form an epoxy foam.

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Albuquerque, NM, United States of America

Mathias C Celina