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Cross-section of the target chamber in an artist’s concept of an inertial fusion energy power plant

LLNL researchers have developed additive manufactured fuel targets for IFE.  They have been successful in using TPL to fabricate low density (down to 60 mg/cm3) and low atomic number (CHO) polymeric foams for potential targets, and some have been tested at the OMEGA Laser Facility. With TPL, LLNL researchers have also been able to fabricate a full fuel capsule with diameter of ~ 5mm or…

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Printed lattice structure using conductive elastomeric composite DIW ink formulation

LLNL researchers have developed a silicone based conductive, elastomeric 3D DIW printed structure with a lower wt.% conductive, composite filler to allow for the creation of 3D printed lattice structures with tunable conductivity.   The conductivity of the printed structure can be varied using composition of the starting DIW ink formulation as well as the 3D printed spacing and…

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Metalens Array used for massively parallel Two-Photon Polymerization (TPP)

LLNL researchers have developed a parallelized TPP system that combines metalens array and spatial light modulator (SLM) to manipulate the directed laser light, which enables high-volume fabrication of nano-architected structures at wafer-scale.  Instead of using a single microscope objective, LLNL’s approach uses an array of metalens that the laser passes through with each metalens being…

IPO logo over a face profile with interconnected lines

LLNL researchers have developed a method which utilizes functional alcohols to depolymerize polyurethane crosslinked networks. The functional alcohols show 5X increase in the depolymerization efficiency compared with current state of art (e.g. methanol, ethylene glycol).  The crosslinked polyurethane networks completely depolymerized into a liquid oligomer within 48 hours at ambient…

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3D printed Gyroid structure using novel long shelf-life silicone formulation

LLNL researchers have developed a novel photocurable silicone useful for producing three-dimensional objects via additive manufacturing. The resin formulations consist of a mult-component siloxane polymers with different functionalities, a platinum catalyst, a photoinitiator, and other organic peroxides.  The LLNL invention involves controlling the spatial and temporal aspects of the…

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Picture of SLA printed structures using 3D printable nitrile-containing photopolymer resins

LLNL’s invention is a photopolymerizable polymer resin that consists of one or more nitrile-functional based polymers. The resin is formulated for SLA based 3D printing allowing for the production of nitrile-containing polymer components that can then be thermally processed into a conductive, highly graphitic materials. The novelty of the invention lies in (1) the photo-curable nitrile-…

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Examples of different UV exposure patterns printed from the same multi-material resin.  Darker yellow regions have higher UV exposure times leading to tougher regions.

LLNL researchers have developed an innovative and uniform single-pot polymer multi-material system, based on a combination of 3 different reactive chemistries.  By combining the three different constituent monomers, fine control of mechanical attributes, such as elastic modulus, can be achieved by adjusting the dosage of UV light throughout the additive manufacturing process.  This…

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Sequential self-folding of 2D polyimide sheets into 3D microsystems

The approach involves 3D printing hinges made of Pre-Stressed Polymers (“PSP”) onto polyimide (“PI”) substrates.  These hinges are then able to fold in response to externally applied stimuli, such as light.  First, 2D PI devices will be microfabricated.  Then, PSP infused with colored inks will be printed using Direct Ink Write (“DIW”) on the hinges of the PI devices.  When…

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3D Printing of Ultem® at Ambient Conditions

The novel approach is to make Ultem® into an ink for DIW or droplet printing by dissolving Ultem® in solvents, such as tetrahydrofuran.  This produces a viscous solvent-melt that is loaded into an ambient temperature extrusion system and deposited into a defined structure by the 3D printer.  Solvent mobility is limited by the polymer structure, and further solvent removal allows…

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Two-photon lithography print configuration modes: (a) traditional immersion medium vs. (b) dip-in laser lithography. (c) Scanning electron micrographs of a 2.5 mm tall pillar in the form of a gyroidal lattice printed in dip-in lithography with a photo-resin with a refractive index of 1.52

LLNL’s approach to producing refractive index matching (RIM) resin is to use a commercially available material known as polyhedral oligomeric silsesquioxane (POSS) precursors.  To tune the refractive index, POSS can be functionalized with additives such as phenylthiol, until the refracted index match is achieved.  For example, for a 1.4 NA oil objective lens, a RIM resin with a…