9420356 Calvert The research is for development of a solid freeform fabrication system based on extrusion of a fine jet of polymerizable slurry. Three-dimensional parts are build up as a series of layers under computer control, based on part geometry data stored in the computer. Preliminary results have been obtained in conjunction with a local small business. The researched work will use two joined heads so that two-component reagents can be used, allowing parts to be formed from a wide range of strong polymers and from organic/inorganic hybrids by coextrusion of alkoxide/monomer mixtures and water/monomer mixtures. It will also allow composite materials to be formed with compositional gradients, or with short-fiber reinforced composites, such that mechanical properties can be locally optimized. Reinforced composites will be designed using finite element methods to seek optimal distributions of reinforcements. Rapid prototyping to near net shape offers numerous advantages in terms of reducing cycle time, waste, and thus manufacturing costs. The ability to make complex composites should open the way to biomimetic and intelligent materials which can achieve levels of damage resistance and responsiveness found in biological materials.
