Northeastern University

3dfortify, Inc.

Massachusetts Institute of Technology

Trustees of the Colorado School of Mines

Randall Erb

Joshua J Martin

Daniel Shores

Yet-Ming Chiang

Jonathan Samuel Sander

Melissa D Krebs

Anvesh Gurijala

Noah E Tremblay

Linsen Li

Kelli Ann Lynch

Andrew Caunter

Conor Doyle

Tyler Hall

Isabel Welch

Peter Christensen

Evan Toth

Jessica Faust

Li Zhang

Robert Zando

Jabulani R T Barber

Ataollah Mesgarnejad

Alain Karma

Ryan Pembroke

Scott Goodrich

Amy Den Dulk

Qiaochu Han

Composite multilayered material compositions are provided which contain one or more hexagonal boron nitride (hBN)-containing layers, together with layers comprising optional polymeric binders, glass fibers, magneto-ceramic materials, and a super-hydrophobic outer coating. Methods are provided for making the composite materials and products containing them. The composite materials are useful for making radomes and other coverings for electronic components and equipment.

Thermally conductive boron nitride films and multilayered composites containing them

A composite material of particles disposed in a matrix material is provided in which the particles have an asymmetric geometric shape with a longest dimension and a shortest dimension different from the longest dimension. Adjacent volume portions of the composite material are arranged in a mosaic pattern to abut along an interface or surface forming a common boundary between the adjacent volume portions. The particles within the adjacent volume portions are arranged with differing orientations with respect to the interface. The orientations of the particles in the adjacent volume portions are selected so that a crack propagating on a crack propagation path through one or the other of the adjacent volume portions stops at or deflects to propagate along the interface. Methods of making composite materials are also provided.

Ceramic-reinforced polymer composites with herringbone architecture

Methods for forming a coated digitally manufactured part include forming an article by a digital manufacturing method; coating a surface of the article with a reactive silicon-containing precursor polymer; and treating the polymer to form a silica-containing coating, thereby forming the coated digitally manufactured part. An article includes a digitally manufactured part having surface striations; and a coating encapsulating the digitally manufactured part and comprising silica. An article includes a digitally manufactured part (i) formed by selective lase sintering, (ii) comprising a surface defined by coalesced particles, and (iii) having a surface roughness Rof at least 0.1 microns; and a coating encapsulating the part and comprising silica. A composition comprising polysilazane is described.

Surface properties modification of digitally manufactured articles via reactive silicon-containing precursor polymers

Three-dimensional printing methods and systems use a derived geometry and aligns anisotropic inclusions in any orientation at any number of discrete volumetric sections. Structural, thermal, or geometry-based analyses are combined with inclusion alignment computations and print preparation methods and provided to 3D printers to produce composite material parts that meet demanding geometric needs as well as enhanced structural and thermal requirements. In one example, optimal inclusion alignment vectors associated with a section of the object are calculated based on specifications for the object, segmenting a three-dimensional model of the object into layer slices, grouping each section within each layer slice having similar alignment vectors and combining the groupings and generating printing instructions for the object according to the grouped alignment vectors.

Systems and methods for alignment of anisotropic inclusions in additive manufacturing processes

An apparatus and method for producing a composite part, such as a reinforced composite part, are provided that enable control over the fiber or other particle orientation within each layer of the part during manufacture. The apparatus and method employ a print head including a dispensing tip and a magnetic assembly controllable to apply a magnetic field at a print location adjacent the dispensing tip outlet.

Direct write three-dimensional printing of aligned composite materials

Additive manufacturing systems and methods for non-planar interfaces between layers

In an embodiment, a process for making a thermal interface article comprises shaping a flowable composite comprising a flowable matrix composition, a plurality of magnetic, thermally conductive particles having an average length greater than a thickness or diameter, wherein the plurality of magnetic, thermally conductive particles have magnetic or superparamagnetic nanoparticles attached thereto, to provide the flowable composite in a shape comprising a first surface and an opposing second surface, and having a Z-axis perpendicular to the first surface and the opposing second surface; subjecting the flowable composite to a rotating magnetic field and to a vibrational force in an amount and for a time effective to align the average length of the plurality of magnetic, thermally conductive particles along the Z-axis; and solidifying the flowable matrix composition to provide the thermal interface, wherein the thermal interface has a Z-direction thermal conductivity of at least 1.0 W/mK.

Methods for the manufacture of thermal interfaces, thermal interfaces, and articles comprising the same

A method and apparatus for producing a composite part are provided to enable composite parts to be assembled with precise control over the orientation and spatial distribution of reinforcing or other particles within a matrix material. The method and apparatus use magnetic fields applied during various additive manufacturing processes to achieve complex particles orientations within each layer of the part. The composite parts can achieve enhanced properties, including mechanical, thermal, electrical and optical properties.

Additive manufacturing of discontinuous fiber composites using magnetic fields

The use of magnetic fields in the production of porous articles is generally described. Certain embodiments are related to methods of producing porous articles in which magnetic fields are applied to an emulsion to align emulsion droplets. In some embodiments, after the emulsion droplets have been aligned, the emulsion droplets and/or the medium surrounding the emulsion droplets can be removed to leave behind a porous article. According to certain embodiments, polyvinyl alcohol can be used, for example, to stabilize the emulsion droplets and/or bind together components of the porous article. In some embodiments, water-soluble liquid alcohol can be used, for example, to stabilize the suspension of electronically conductive material within a phase of the emulsion.

Magnetic field alignment of emulsions to produce porous articles

Augmented three-dimensional (3D) printing systems and methods for constructing and mineralizing a hydrogel structure with defined geometry are disclosed. One example embodiment is a system for three-dimensional printing and mineralizing a polymer. The system includes a three-dimensional printer unit with a syringe extruder, a fluid delivery system operatively coupled to the three-dimensional printer unit, and a control unit. The control unit is operatively coupled to the three-dimensional printer unit and fluid delivery system, and is configured to (i) cause the three-dimensional printer unit to print a portion of a three-dimensional polymer object, (ii) cause the fluid delivery system to flush the portion of the three-dimensional polymer object with a fluid to mineralize the portion of the three-dimensional polymer object, and (iii) cause the three-dimensional printer unit to print a subsequent portion of the three-dimensional polymer object. Applications of embodiments include manufacturing of tooth, bone, and other biomaterial articles.

Three dimensional mineralization printer

The use of magnetic fields in the production of porous articles is generally described. Certain embodiments comprise exposing a matrix to a magnetic field such that particles within the matrix form one or more elongated regions (e.g., one or more regions in which the particles chain). In some embodiments, after the magnetic field has been applied, the particles and/or a liquid within the matrix can be at least partially removed. Removal of the particles and/or the liquid can leave behind anisotropic pores within the remainder of the matrix material.

Pore orientation using magnetic fields

Growing community of inventors

Newton, MA, United States of America

Randall Erb