19 Sep 2025

Design and Development of Large Format Additive Manufacturing Techniques

Abstract: This report discusses the creation of a large format additive manufacturing (LFAM) printer and initial test printing with the machine. A pellet-extruder head was attached to a computer numerical control (CNC) gantry. The team at the US Army Research and Development Center (ERDC) modified gantry arms to increase build height and designed electronic controls to allow for control of the printhead and the heated print bed. This report also covers print parameter optimization and print settings development.

2 Sep 2025

Morphology Control in Waterborne Polyurethane Dispersion Nanocomposites Through Tailored Structure, Formulation, and Processing

Abstract: Waterborne polyurethane dispersions (PUDs) have garnered increasing interest in recent years due to the growing demand for environmentally friendly materials. The unique phase-separated morphologies exhibited in PUD films and coatings provide opportunities for directing the distribution of functional additives and controlling properties. Although there has been extensive research on polyurethanes for several decades, the mechanisms underlying the PUD morphology formation are poorly understood. The morphologies are driven by interactions between hard segments (HS), and the process is further complicated by the presence of colloidal particles and the intricate interaction between the urethane/urea linkages and water. In this work, structure−property-processing relationships between HS content and structure, relative humidity, particle size, and the resulting dry film morphology of PUDs were determined in two diisocyanate systems: hexamethylene diisocyanate (HDI), a symmetric, flexible diisocyanate; and isophorone diisocyanate (IPDI), an asymmetric, sterically hindered cyclic diisocyanate. HDI-based films exhibited semicrystalline morphologies with HS superstructures that are sensitive to relative humidity. IPDI-based films displayed spherical coalescence-suppressed morphologies influenced by particle size and zeta potential. PUD compositions and processing conditions were controlled to produce nanocomposite films with an enhanced dispersion of nanoadditives.

29 Aug 2025

Nanofiber Fabrication by Electrospinning Technology: Optimization, Characterization, and Application

Abstract: This project explores electrospinning (ES) as one of the most successful technologies to produce nanofiber materials. Electrospun nanofibers are used in various military technologies, including advanced filtration systems, impact-resistant protective gear, thermal insulation, radar absorption for camouflage and stealth, antimicrobial wound dressings, drug-delivery patches, rapid healing, efficient solar cells, and self-cleaning materials for regeneration. Researchers at the US Army Engineer Research and Development Center (ERDC) investigated electrospinning effects on morphology, crystallinity and distribution of metal oxides for photocatalytic activities, and magnetic and mechanical properties in reinforcing composites. This study includes the following fabricated electrospun mats: -iron and titanium oxide (Fe3O4 and TiO2) with polyvinyl alcohol (PVA) -graphene, graphene oxide, and reduced graphene oxide with polyvinylidene fluoride (PVDF) -graphene-polyacrylonitrile (PAN) -metal-organic frameworks (MOF), graphene-MXene with PAN The research presented herein includes electrospinning theory, process, and parameters; sol–gel technology in solution preparation; and electrospinning sample characterization to guide readers in the fabrication of electrospun fibers with targeted characteristics. Future studies explore electrospun MOFs and MXene, a class of two-dimensional inorganic compounds with transition metal carbides, nitrides, or carbonitrides composites. These studies are invaluable for advancing military programs and enhancing warfighter support and civil works.