Synthesis of Nanomaterial-based Coatings, Fillers, Composites, 3D Printing Inks, and Sensors

National Laboratory: 
Sandia National Laboratories
Processing/Manufacturing Class: 
Fabrication and synthesis
Description: 

The Advanced Materials Laboratory (AML) has in-house synthetic capabilities and characterization tools for the production of nanomaterial (metal, semi-conductor, ceramic [oxide, pnictide])-based composites, coatings, three-dimensional (3D) printing inks, and printed sensors to enhance or interrogate performance of lightweight materials. Examples of past development include development of lightweight, nanostructured composite flywheels and development of sensor technology to monitor composite performance in order to support structural health monitoring. AML staff are available to guide development of new precursors, materials, redesign formulations, and product integration.

Nanoparticle and Ink Synthetic Capabilities: Inert Atmosphere Gloveboxes, Schlenk Lines, Parr Digestion Bombs, Pressure Reactors, Microwave Ovens  

Direct Write Fabrication Tools: 3D printing (Aerosol Jet, Ink Jet, Robocasting), DLS Particle Size Measurement, Zeta potential characterization with pH Titration, Dynamic Wave Spectroscopy (Zero shear Elastic and Viscoelastic modulus, Rheological Measurement (MARS II ThermoFisher), Turbiscan dispersion stability measurement, Film Gelation/Drying Characterization, Contact Angle, Squeeze Flow Rheometry, Extensional Rheometry.

Post Processing Tools for Printed Components: Laser, Flash Lamp, Bulk Thermal, Electrical Arc Sintering.

Capability Bounds: 

Synthesis: Small (1–50 mL) to medium scale  (100 - 3000 mL)  to large (30–150 L) reactors are available. Sample batches of nanomaterials, from mg to several kg, can be produced.

Unique Aspects: 

We have developed composites, coatings, inks, nanofillers, and sensors for:

  • EERE Water Power Technologies Office Marine Hydrokinetic Energy Program: Developed protective nano anticorrosion and antifouling coatings
  • EERE Office of Energy Flywheels Program: Developed Ceramic-resin nanocomposite with improved 'strength' of 20-30 % for flywheel applications
  • Novel metal inks (i.e., Cu, Ni, Co etc.) for Direct Write (3D Printing) applications
  • Ceramic-resin nanocomposite with improved “strength” of 20–30 % for flywheel applications.
Availability: 

Availability of synthesis processes is coordinated by a SNL capability expert.

Single Point of Contact: 

Name: Randall Schunk, Advanced Materials Laboratory Manager
Email: prschun@sandia.gov
Phone: (505) 272-7602

Supporting Document(s):