Tuning the 3D Printability and Thermomechanical Properties of Radiation Shields

3D Printing of Composite Radiation Shielding for Broad Spectrum Protection of Electronic Systems

The miniaturization of satellite systems has compounded the need to protect microelectronic components from damaging radiation. Current approaches to mitigate this damage, such as indiscriminate mass shielding, built-in redundancies, and radiation-hardened electronics, introduce high size, weight, power, and cost penalties that impact the overall performance of the satellite or launch opportunities. Additive manufacturing provides an appealing strategy to deposit radiation shielding only on susceptible components within an electronic assembly. Here, a versatile material platform and process to conformally print customized composite inks at room temperature directly and selectively onto commercial-off-the-shelf electronics is described. The suite of inks uses a flexible styrene-isoprene-styrene block copolymer binder that can be filled with particles of different atomic densities for diverging radiation shielding capabilities. Additionally, the system enables the combination of multiple distinct particle species within the same printed structure. The method can produce graded shielding that offers improved radiation attenuation by tailoring both shield geometry and composition to provide comprehensive protection from a broad range of radiation species. The authors anticipate this alternative to traditional shielding methods will enable the rapid proliferation of the next generation of compact satellite designs.

Interplay between Shelf Life and Printability of Silica-Filled Suspensions

Although fumed silica/siloxane suspensions are commonly employed in additive manufacturing technology, the interplay between shelf life, storage conditions, and printability has yet to be explored. In this work, direct ink writing (DIW) was used to print unique three-dimensional structures that required suspensions to retain shape and form while being printed onto a substrate. Suspensions containing varying concentrations of hydrophobic and hydrophilic silica were formulated and evaluated over a time span of thirty days. Storage conditions included low (8%) and high (50%) relative humidity and temperatures ranging from 4 °C to 25 °C. The shelf life of the suspensions was examined by comparing the print quality of pristine and aged samples via rheology, optical microscopy, and mechanical testing. Results showed a significant decrease in printability over time for suspensions containing hydrophilic fumed silica, whereas the printability of suspensions containing hydrophobic fumed silica remained largely unchanged after storage. The findings in this work established the following recommendations for extending the shelf life and printability of suspensions commonly used in DIW technology: (1) higher fumed silica concentrations, (2) low humidity and low temperature storage environments, and (3) the use of hydrophobic fumed silica instead of hydrophilic fumed silica.

Balancing Functionality and Printability: High-Loading Polymer Resins for Direct Ink Writing

Although direct ink writing (DIW) allows the rapid fabrication of unique 3D printed objects, the resins-or "inks"-available for this technique are in short supply and often offer little functionality, leading to the development of new, custom inks. However, when creating new inks, the ability of the ink to lead to a successful print, or the "printability," must be considered. Thus, this work examined the effect of filler composition/concentration, printing parameters, and lattice structure on the printability of new polysiloxane inks incorporating high concentrations (50-70 wt%) of metallic and ceramic fillers as well as emulsions. Results suggest that strut diameter and spacing ratio have the most influence on the printability of DIW materials and that the printability of silica- and metal-filled inks is more predictable than ceramic-filled inks. Additionally, higher filler loadings and SC geometries led to stiffer printed parts than lower loadings and FCT geometries, and metal-filled inks were more thermally stable than ceramic-filled inks. The findings in this work provide important insights into the tradeoffs associated with the development of unique and/or multifunctional DIW inks, printability, and the final material's performance.

Composites Additive Manufacturing for Space Applications: A Review

The assembly of 3D printed composites has a wide range of applications for ground preparation of space systems, in-orbit manufacturing, or even in-situ resource utilisation on planetary surfaces. The recent developments in composites additive manufacturing (AM) technologies include indoor experimentation on the International Space Station, and technological demonstrations will follow using satellite platforms on the Low Earth Orbits (LEOs) in the next few years. This review paper surveys AM technologies for varied off-Earth purposes where components or tools made of composite materials become necessary: mechanical, electrical, electrochemical and medical applications. Recommendations are also made on how to utilize AM technologies developed for ground applications, both commercial-off-the-shelf (COTS) and laboratory-based, to reduce development costs and promote sustainability.