CAGE code 7RS73: IC3D’s Government Research Activities

For those in the Government and Department of Defense sectors eager to understand our SBIR projects and CRADA collaborations in additive manufacturing, we welcome you to reach out directly. With our active CRADA, there exists an optimal platform to integrate fresh perspectives and ideas with minimized red tape.

Keywords we work with: additive manufacturing, 3D printing, digital manufacturing, distributed manufacturing, rapid prototyping, rapid production, tooling, MRO (maintenance, repair, overhaul / operations), quality control, contested logistics, qual cert (qualification certification), digital thread, defense logistics.

U.S. Army DEVCOM C5ISR Center SBIR Phase I & II (completed)

“High Temperature Polymers for 3D Printed Injection Molding Tooling”

Abstract:

The repair and rebuilding of injection molded parts is an important activity at army depots. The unit cost to make small batch parts is quite expensive due to the high cost and long lead time for injection molds for tooling.  Fused Filament Fabrication AM offers a viable alternative to reduce tooling costs and lead time, however most AM thermoplastics do not meet the stringent requirements of high-pressure injection molding tooling.  We propose to explore various compounds of carbon and glass fiber-filled polymers to identify those with suitable properties to make into filaments for injection molded tooling. The project will also equip commercial-off-the-shelf (COTS) desktop 3D printers to handle the high temperatures and abrasive materials and develop a low-cost upgrade package developed for retro-fitting. These results will play a important role in increasing readiness by reducing tooling costs and lead times for MRO activities.

National Institute of Standards and Technology (NIST) SBIR Phase I & II (Active)

“Regionalized Quality Control Centers for Mobilization of Distributed Additive Manufacturing”

Abstract:

Early in the covid pandemic, decentralized and democratized AM of PPE was activated to alleviate supply chain failures that prevented normal suppliers of devices like face shields to meet the demands of the domestic health care system. Quality control testing, while critical to reducing risk by ensuring appropriate, safe, and reliable parts, is a time intensive and equipment intensive process. As a result, small manufacturers producing 3D printed parts outside their typical industry, or even volunteer hobbyist 3D printers producing parts, were unable to appropriately access sufficient quality control testing facilities or expertise, given the emergency activation of the regionalized production. IC3D proposes to address the access to appropriate quality control testing by piloting a regional AM quality control center. These regional centers will coordinate with local NIST Manufacturing Extension Partnership (MEP) organizations to establish quality control logistics and testing availability for small businesses and citizen-manufacturers during times of national emergency. During non-emergency times, these centers will provide commercial, fee-for-service outsourcing of quality control testing for small AM businesses, reducing a significant barrier to entry for small businesses into the medical supply market.

CRADA: U.S. Army DEVCOM Chemical Biological Center & Naval Information Warfare Center Pacific

Polymer Material Research for Fused Filament Fabrication Additive Manufacturing

The purpose of this CRADA is to enable NIWC Pacific, DEVCOM CBC, and IC3D to conduct collaborative research and development in the material properties of new and existing polymer materials for Fused Filament Fabrication (FFF) additive manufacturing (AM). The objective of this CRADA is to document material properties data and FFF AM process data for joint use by the Collaborators. This research will cover form factors of material including but not limited to filament printing as well as direct pellet fed FFF printing.

U.S. Department of Energy & Ohio University (Active)

“Fused Deposition Modeling Additive Manufacturing of Carbonized Structures via Waste-Enhanced Filaments“

IC3D Inc. is collaborating with Ohio University on a project focused on the development of carbonized structures using waste-enhanced filaments in additive manufacturing. IC3D, which integrates traditional manufacturing with 3D printing technologies, will contribute to the creation and evaluation of coal-enhanced filaments, aiming to explore alternative applications for coal. The company’s role includes participating in large-scale 3D printing experiments and assisting with techno-economic assessments, supported by a combination of financial and in-kind contributions.

America Makes / NCDMM (National Center for Defense Manufacturing & Machining) – Funded by the US Air Force and the Office of the Undersecretary of Defense (Active)

“Accelerating Additive In DoD Applications Of High Performance Recycled Polymers“

IC3D is actively engaged in the Environmental Additive Research for Tomorrow’s Habitat (EARTH) project aimed at advancing additive manufacturing (AM) sustainability by leveraging recycled polyethylene terephthalate (rPET) materials for 3D printing. As a leader in this initiative, IC3D’s role is pivotal in developing and validating robust rPET and rPET-based composite materials suitable for filament-fed 3D printers. Their commitment to the EARTH project reflects their broader objective to enhance the sustainability of AM processes by integrating readily available recycled materials. IC3D’s expertise in polymer filament production and 3D printing technology is crucial to overcoming the existing challenges related to the printability and performance of rPET materials, thereby promoting a commercially viable and environmentally responsible future for additive manufacturing.