Project Work
Phase 1:
Prepare a theoretical-numerical model explaining metallic particle acceleration that can be used to define the best test set-up for electrostatic powder acceleration
Activities:
Preparing a comprehensive FE model of an electrostatic accelerator to evaluate its impact on particle velocity. Understanding parameter sensitivity and simulating transient voltage effects on velocity with different accelerator parameters to study stability and impact focus. Simulating particle-substrate contact using velocity and temperature profiles to assess bonding.
Phase 2:
Activities:
Develop, test, and optimize a particle charger with acceleration stage and electronics. Upgrade micron-dust source and detector for higher charges and larger particles and experiment on dust accelerator. Explore beam parameters and dust material selection with a setup including dust reservoir, launching unit, collimating system, charge induction electrode, amplifier, and vacuum system.
Phase 3:
Development of micro electromechanical gates for continuous modulated feed and launch system
Activities:
Development of electromechanical gate designs including material selection, defining control configurations, and conducting multiphysics simulations. Simulating various design options to test control elements and compare performance parameters such as reliability and frequency. Preparing multidomain simulation models to validate configurations considering material and dimensions which will represent physical operation and serve as a digital twin.
Phase 4:
Verify and develop operating conditions of the integrated matrix feeder and launcher
Activities:
Fabrication of a matrix of parallel channels with strict tolerances for particle interaction analysis. Utilizing designed gates for trajectory assessment and realignment. Implementing powder feeder for continuous particle replacement. Develop hardware and software for precise channel control for accurate deposition. Mount setup on a three-axis positioner for optimal testing, including distance and angle adjustments for feed forward control.
Phase 5:
Validating 3D printing functionality and its manufacturing applications in different sectors.
Activities:
Assessing multi-channel acceleration control via 3D printing of samples, starting with basic shapes like cubes or dog-bones. Samples sized for full-scale analysis, with alternating layers of Materials A and B to explore various properties. Comparing costs with other AM methods, evaluating energy efficiency and proof of concept against Key Characteristics.
Aerospace Sector: Validate our new multi-material printing system for small satellite thruster prototypes, ensuring heat resistance, lightweight design, and superior mechanical properties in extreme conditions.
Energy Sector: MadeCold aims to enhance heat transfer and boost energy system efficiency through ultra multi-scale textured surfaces and lattice structures.
Hybrid Manufacturing Sector: Demonstrating MadeCold’s accuracy and precision through precision deposition on existing parts, customizing structures to reduce automotive panel weight within tolerances, achieving net shape without post-processing.