SBIR-STTR Award

Raven 3D, the University of Oklahoma (OU), Gerling Consulting, Inc. (GCI), and Güdel Inc. propose to develop FiberQuill, a scalable Direct Ink Writing (DIW) 3D printing method capable of printing epoxy coated continuous carbon fiber (e-CCF) to fabricate extraordinarily high strength-to-weight ratio aircraft parts. In the Phase I effort, the team will develop the FiberQuill printhead that uses microwave energy to cure the extruded e-CCF immediately after deposition to enable continuous carbon fiber (CCF) DIW for the needs of the Air Force. For Phase II and beyond, the 3D printing technique can be scaled-up to larger build volumes utilizing robotic manufacturing systems provided by Güdel. FiberQuill will enable 3D printing of large carbon fiber composite structures with comparable mechanical and thermal properties to composite laminates. This technology will allow the Air Force and the aerospace industry to manufacture optimally designed composite aircraft components that were previously unable to be fabricated via molding. FiberQuill will improve the performance, reduce the number of parts, and simplify maintenance for cutting edge composite aircraft.

In the Phase II project proposed, Raven 3D will continue developing the Phase I desktop 3D printer prototype to provide on-demand fabrication of thermoset parts like gaskets, O-rings, and aircraft ducting for the Air Force. Additionally, a multi-axis Phase II prototype will be developed to 3D print epoxy matrix continuous carbon fiber parts for extremely high strength, lightweight, and durable parts production. The FiberQuill technology is capable of in-situ curing genuine thermoset materials to enable large-scale 3D printing of complex polymer parts with considerably higher performance than traditionally 3D printed thermoplastics and photopolymers. Raven 3D will utilize its key partnerships and experienced research team to leverage our cutting-edge technologies to greatly improve the proof of concept prototype that was developed in Phase I for immediate AF use and develop a groundbreaking multi-axis thermoset 3D printing technology. The Phase II work will result in small and large-scale 3D printing of high-performance thermoset polymer parts, with unprecedented resistance to heat, chemicals, and light for several Air Force applications.