Magnetic Powders and Heterogeneous Gradient Additive Manufacturing Techniques
Navy SBIR FY2015.1


Sol No.: Navy SBIR FY2015.1
Topic No.: N151-029
Topic Title: Magnetic Powders and Heterogeneous Gradient Additive Manufacturing Techniques
Proposal No.: N151-029-0761
Firm: Voxtel Inc.
15985 NW Schendel Avenue
Suite 200
Beaverton, Oregon 97006
Contact: Sean Keuleyan
Phone: (971) 223-5646
Web Site: www.voxtel-inc.com
Abstract: A breakthrough, scalable, high-volume process for manufacturing known-quality low-loss, high-index, and high-wave characteristic impedance magnetic powders with particular electromagnetic characteristics and additive manufacturing (AM) processes will be developed, which allow for fabrication of functional materials with 3D-graded electromagnetic properties. The materials and processes will be optimized for use in manufacturing advanced radomes, with enhanced performance and protection of antennas from weather elements. Using magnetic ceramics and magneto-dielectric polymer nanocomposite inks, fabricated using scalable processes, and deposited using inkjet print and powder-bed fusion AM fabrication, a series of homogeneous and heterogeneous samples will be fabricated, and their physical and magneto-dielectric properties measured. Then it will be shown how 3D freeform magneto-dielectric structures can be fabricated, using scalable AM processes and hardware. These structures will include multiple materials, including metals, plastics, and composites. The demonstration and characterization of the materials and processes will reduce the risk of the Phase II program, wherein the readiness level of the technology will be increased, and functional parts will be fabricated and qualified.
Benefits: The ability to place dielectric and magneto-dielectric nanocomposites into 3D freeform structures, using low-cost, scalable additive-manufacturing (AM) techniques enables widespread use in fabricating advanced antennas, insulators, optics, photonic circuits, and electronics for a wide range of consumer, automotive, and military applications.

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