The Center for Additive Materials (CAM) has been established by HRL Laboratories, LLC to accelerate the development of high performance materials for additive manufacturing processes. With the rapid introduction of additive processes into more and more industries, the portfolio of materials available for 3D printing plays a key role in defining the success of the additive manufacturing revolution. CAM is dedicated to broaden the property space accessible via additive manufacturing. Key focus areas include:
HRL is uniquely positioned for a leadership role in the science and engineering of additive manufacturing: We are informed by the latest technological challenges of our LLC members (Boeing & GM) and our Government customers as we maintain strong ties with universities, national labs and other innovative companies.
The unique solidification conditions during metal additive manufacturing drastically limit the number of alloys that can be processed today. This has hindered metal additive manufacturing from reaching its full potential to transform design and fabrication and disrupt multiple industries. HRL has developed a metallurgical approach to drastically expand the alloys amenable to processing with existing additive manufacturing hardware. Our approach is based on manipulating solidification mechanisms via functionalization of feedstock powders with nanoparticle nucleants selected using crystallographic informatics. We have demonstrated the effectiveness of this approach by successfully selective laser melting aluminum alloy Al7075 and Al6061 powders resulting in crack-free, equiaxed, fine-grained microstructure and yield strength comparable to wrought material.
The extremely high melting point of many ceramics adds challenges to additive manufacturing as compared with metals and polymers. Because ceramics cannot be cast or machined easily, 3D printing enables a big leap in geometrical flexibility. HRL has developed preceramic resin systems that can be cured with ultraviolet light in commercially available stereolithography 3D printers or through a patterned mask. Polymer structures with complex shape can be formed and then pyrolyzed to a ceramic with uniform shrinkage and virtually no porosity. Silicon oxycarbide structures fabricated with this approach exhibit high strength and withstand temperatures up to 1700C.
HRL has developed a platform technology to rapidly and scalably manufacture architected lattice materials based on polymers, metals, and ceramics suitable for a variety of applications. Architected materials with periodic cellular structure exhibit unprecedented properties that cannot be achieved with conventional materials. A self-propagating polymer waveguide process invented at HRL is used to additively manufacture architected polymer lattice structures 100-1000x faster than conventional 3D printing approaches such as stereolithography. HRL’s process is inherently scalable to large areas in addition to offering high throughput. HRL has developed photo polymer formulations for a broad range of applications including:
Sandwich structures are unique enablers of lightweight design, as they offer an exceptional combination of low density and high bending rigidity. Lightweight sandwich structures are widespread in aerospace applications (e.g. winglets, flaps, rudders, rotor blades) but are also used in many other industries. State-of-the-art sandwich panels are created by attaching thin, stiff composite or aluminum alloy facesheets to thick, lightweight honeycomb or foam cores. HRL has developed advanced core materials based on hollow metallic truss structures that offer improved compressive and shear strengths versus honeycombs. Hollow truss structures are preferably fabricated by coating a polymer template of the truss structure, which is subsequently removed. This approach converts a 2D thin film or coating into a 3D cellular material, thereby redefining the applications of a range of thin film/coating materials.
Authors | Title | Publication | Year |
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Martin, John H; Ashby, David S; Schaedler, Tobias A; | Thin-walled high temperature alloy structures fabricated from additively manufactured polymer templates | Materials & Design, vol 120, p 291-297 | 2017 |
J.H. Martin, B.D. Yahata, J.M. Hundley, J.A. Mayer, T.A. Schaedler, T.M. Pollock | 3D Printing of High-Strength Aluminium Alloys | Nature, vol 549, p 365-371 | 2017 |
J.M. Hundley, Z.C. Eckel, E. Schueller, K. Cante, S.M. Biesboer, B.D. Yahata, T.A. Schaedler | Geometric Characterization of Additively Manufactured Polymer Derived Ceramics | Additive Manufacturing, vol 18, p 95-102 | 2017 |
T.A. Schaedler, L.J. Chan, E.C. Clough, M.A. Stilke, J.M. Hundley, L.J. Masur | Nanocrystalline Aluminum Truss Cores for Lightweight Sandwich Structures | JOM | 2017 |
Bauer, J; Meza, LR; Schaedler, TA; Schwaiger, R; Zheng, X; Valdevit, L; | Nanolattices-An Emerging Class of Mechanical Metamaterials | Advanced Materials, p 170, p 1850 | 2017 |
Erdeniz, Dinc; Schaedler, Tobias A; Dunand, David C; | Deposition-based synthesis of nickel-based superalloy microlattices | Scripta Materialia, vol 138, p 28-31 | 2017 |
Faber, Katherine T; Schaedler, TA; et al; | The role of ceramic and glass science research in meeting societal challenges: Report from an NSF‐sponsored workshop | Journal of the American Ceramic Society, vol 100, p 1777-1803 | 2017 |
Clough, Eric C; Ensberg, Jie; Eckel, Zak C; Ro, Christopher J; Schaedler, Tobias A; | Mechanical performance of hollow tetrahedral truss cores | International Journal of Solids and Structures, vol 91, p 115-126 | 2016 |
Eckel, Zak C; Zhou, Chaoyin; Martin, John H; Jacobsen, Alan J; Carter, William B; Schaedler, Tobias A; | Additive manufacturing of polymer-derived ceramics | Science, vol 351, p 58-62 | 2016 |
Schaedler, Tobias A; Carter, William B; | Architected Cellular Materials | Annual Review of Materials Research, vol 46, p 187-210 | 2016 |
Cordes, Nikolaus L; Henderson, Kevin; Stannard, Tyler; Williams, Jason J; Xiao, Xianghui; Robinson, Mathew WC; Schaedler, Tobias A; Chawla, Nikhilesh; Patterson, Brian M; | Micro-scale X-ray Computed Tomography of Additively Manufactured Cellular Materials under Uniaxial Compression | Microscopy and Microanalysis, vol 21, p 129-130 | 2015 |
Hundley, J. M.; Clough, E. C.; Jacobsen, A. J.; | The low velocity impact response of sandwich panels with lattice core reinforcement | International Journal of Impact Engineering, vol 84, p 64-77 | 2015 |
Kolodziejska, JA; Roper, CS; Yang, SS; Carter, WB; Jacobsen, AJ; | Research Update: Enabling ultra-thin lightweight structures: Microsandwich structures with microlattice cores | APL Materials, vol 3, p 50701 | 2015 |
Roper, Christopher S; Schubert, Randall C; Maloney, Kevin J; Page, David; Ro, Christopher J; Yang, Sophia S; Jacobsen, Alan J; | Scalable 3D bicontinuous fluid networks: Polymer heat exchangers toward artificial organs | Advanced Materials, vol 27, p 2479-2484 | 2015 |
Liu, Yilun; Schaedler, Tobias A; Chen, Xi; | Dynamic energy absorption characteristics of hollow microlattice structures | Mechanics of Materials, vol 77 | 2014 |
Liu, Yilun; Schaedler, Tobias A; Jacobsen, Alan J; Chen, Xi; | Quasi-static energy absorption of hollow microlattice structures | Composites Part B: Engineering, vol 67, p 39-49 | 2014 |
Liu, Yilun; Schaedler, Tobias A; Jacobsen, Alan J; Lu, Weiyi; Qiao, Yu; Chen, Xi; | Quasi-static crush behavior of hollow microtruss filled with NMF liquid | Composite Structures, vol 115, p 29-4 | 2014 |
Rys, Jan; Valdevit, Lorenzo; Schaedler, Tobias A; Jacobsen, Alan J; Carter, William B; Greer, Julia R; | Fabrication and Deformation of Metallic Glass Micro‐Lattices | Advanced Engineering Materials, vol 16, p 889-896 | 2014 |
Salari-Sharif, Ladan; Schaedler, Tobias A; Valdevit, Lorenzo; | Energy dissipation mechanisms in hollow metallic microlattices | Journal of Materials Research, vol 29, p 1755-1770 | 2014 |
Schaedler, Tobias A; Ro, Christopher J; Sorensen, Adam E; Eckel, Zak; Yang, Sophia S; Carter, William B; Jacobsen, Alan J; | Designing metallic microlattices for energy absorber applications | Advanced Engineering Materials, vol 16, p 276-283 | 2014 |
Valdevit, Lorenzo; Godfrey, Scott W; Schaedler, Tobias A; Jacobsen, Alan J; Carter, William B; | Compressive strength of hollow microlattices: Experimental characterization, modeling, and optimal design | Journal of Materials Research, vol 28, p 2461-2473 | 2013 |
Yin, S., Jacobsen, A. J.; Wu, L.; Nutt, S. R. | Inertial stabilization of flexible polymer micro-lattice materials | Journal of Materials Science, vol 48, p 6558-656 | 2013 |
Maloney, Kevin J; Roper, Christopher S; Jacobsen, Alan J; Carter, William B; Valdevit, Lorenzo; Schaedler, Tobias A; | Microlattices as architected thin films: Analysis of mechanical properties and high strain elastic recovery | APL Material, vol 1, p 22106 | 2013 |
Schaedler, Tobias A; Jacobsen, Alan J; Carter, Wiliam B; | Toward lighter, stiffer materials | Science, vol 341, p 1181-1182 | 2013 |
Bernal Ostos, J.; Rinaldi, R. G.; Hammetter, C. I.; Stucky, G. D.; Zok, F. W.; Jacobsen, A.J.; | Deformation stabilization of lattice structures via foam addition | Acta Materialia, vol 60, p 6476-6485 | 2012 |
Doty, R. E.; Kolodziejska, J. A.; Jacobsen, A. J.; | Hierarchical Polymer Microlattice Structures | Advanced Engineering Materials, vol 14, p 503-507 | 2012 |
Maloney, Kevin J; Fink, Kathryn D; Schaedler, Tobias A; Kolodziejska, Joanna A; Jacobsen, Alan J; Roper, Christopher S; | Multifunctional heat exchangers derived from three-dimensional micro-lattice structures | International Journal of Heat and Mass Transfer, vol 55, p 2486-2493 | 2012 |
Roper, Christopher S.; Fink, Kathryn D.; Lee, Samuel T.; Kolodziejska, Joanna A.; Jacobsen, Alan J. | Anisotropic convective heat transfer | Microlattice Materials, vol 59, p 622-629 | 2012 |
Torrents, A; Schaedler, TA; Jacobsen, AJ; Carter, WB; Valdevit, L; | Characterization of nickel-based microlattice materials with structural hierarchy from the nanometer to the millimeter scale | Acta Materialia, vol 60, p 3511-3523 | 2012 |
Jacobsen, A. J.; Mahoney, S.; Carter, W. B.; Nutt, S.; | Vitreous carbon micro-lattice structures | Carbon, vol 49, p 1025-1032 | 2011 |
Lian, Jie; Jang, Dongchan; Valdevit, Lorenzo; Schaedler, Tobias A; Jacobsen, Alan J; B. Carter, William; Greer, Julia R; | Catastrophic vs gradual collapse of thin-walled nanocrystalline Ni hollow cylinders as building blocks of microlattice structures | Nano letters, vol 11, p 4118-4125 | 2011 |
Roper, Christopher S; | Multiobjective optimization for design of multifunctional sandwich panel heat pipes with micro-architected truss cores | International Journal of Heat and Fluid Flow, vol 32, p 239-248 | 2011 |
Schaedler, Tobias A; Jacobsen, Alan J; Torrents, Anna; Sorensen, Adam E; Lian, Jie; Greer, Julia R; Valdevit, Lorenzo; Carter, Wiliam B; | Ultralight metallic microlattices | Science, vol 334, p 962-965 | 2011 |
Valdevit, L.; Jacobsen, A. J.; Greer, J. R.; Carter, W. B.; | Protocols for the Optimal Design of Multi-Functional Cellular Structures: From Hypersonics to Micro-Architected Materials | Journal of the American Ceramic Society, vol 94, p s15-s34 | 2011 |
Fink, Kathryn D; Kolodziejska, Joanna A; Jacobsen, Alan J; Roper, Christopher S; | Fluid dynamics of flow through microscale lattice structures formed from self‐propagating photopolymer waveguides | AIChE Journal, vol 57, p 2636-2646 | 2011 |
Evans, A. G.; M. Y. He; V. S. Deshpande; John W. Hutchinson; A. J. Jacobsen; W. Barvosa-Carter; | Concepts for Enhanced Energy Absorption Using Hollow Micro-Lattices | International Journal of Impact Engineering, vol 37, p 947-959 | 2010 |
Jacobsen, A. J.; Barvosa-Carter, W.; Nutt, S.; | Shear behavior of polymer micro-scale truss structures formed from self-propagating polymer waveguides | Acta Materialia, vol 56, p 1209-1218 | 2008 |
Jacobsen, A. J.; Barvosa-Carter, W.; Nutt, S.; | Micro-scale truss structures with three-fold and six-fold symmetry formed from self-propagating polymer waveguides | Acta Materialia, vol 56, p 2540-2548 | 2008 |
Jacobsen, A. J.; Barvosa-Carter, W.; Nutt, S.; | Micro-scale truss structures formed from self-propagating photopolymer waveguides | Advanced Materials, vol 19, p 3892-3896 | 2007 |
Jacobsen, A. J.; Barvosa-Carter, W.; Nutt, S.; | Compression behavior of micro-scale truss structures formed from self-propagating polymer waveguides | Acta Materialia, vol 55, p 6724-6733 | 2007 |
TBA
Email: additive[at]hrl.com
Dr. Hunter Martin
Senior Research Scientist
Director, Center for Additive Materials
Materials & Microsystems Laboratory
HRL Laboratories, LLC
3011 Malibu Canyon Road
Malibu, CA 90265
USA