Develop and validate a flexible additive manufacturing approach using robocasting or direct ink writing to produce large-format, high-density piezoelectric ceramic components with aligned microstructures (textured ceramics) that exceed the performance of conventional dry-pressed ceramics used in undersea sonar and sensor systems.
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Design and formulate shear-thinning ceramic paste/slurry systems compatible with Navy piezoelectric ceramic materials.
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Develop robocasting or direct ink writing methods for consistent layer-by-layer extrusion and structural build-up.
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Investigate binder systems, solids loading, rheology, and nozzle geometries to optimize manufacturability.
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Evaluate methods to align high aspect ratio ceramic platelets during extrusion to create textured microstructures.
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Produce prototype samples in multiple geometries, including:
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Cylinders (~1 OD)
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Rings (>4 OD)
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Conduct or oversee binder burnout, sintering, densification, electrode application, and poling.
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Model material flow, particle alignment, and print dynamics to assess process feasibility.
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Characterize printed and sintered parts for:
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Density
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Surface finish
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Grain/particle alignment
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Texture fraction
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Capacitance (>200 pF target)
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Dielectric constant
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Loss tangent minimization
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Acoustic and resonance performance
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Compare additive-manufactured textured ceramics against traditional non-textured baselines.
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Phase I feasibility concept and technical approach
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Initial prototype geometries and performance data
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Recommendations for Phase II hardware design specifications
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Final technical report summarizing:
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Material formulation
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Manufacturing process
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Performance outcomes
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Risks and transition recommendations
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PhD (completed or ABD with strong publication record) in:
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Materials Science
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Ceramic Engineering
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Mechanical Engineering
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Additive Manufacturing
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Chemical Engineering
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Physics (materials-focused)
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Demonstrated expertise in one or more:
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Piezoelectric ceramics
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Robocasting / Direct Ink Writing
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Rheology of ceramic slurries
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Sintering and densification
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Microstructural characterization
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Functional ceramics or sonar materials
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Experience with technical writing for SBIR/STTR, DoD, ONR, or Navy programs preferred
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Familiarity with lead-based ceramics, textured ceramics, or anisotropic particulate systems strongly preferred
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COMSOL, ANSYS, or similar modeling tools
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SEM/XRD/EBSD or other microstructure analysis techniques
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Electrical/acoustic characterization of piezoelectric materials
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Prototype fabrication and laboratory scale-up planning
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Technology transition strategy for defense or commercial sectors
By the end of the six-month period, the awardee should demonstrate:
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Feasibility of a DIW/robocasting process for Navy piezoelectric ceramics
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Viable pathway to large-format textured ceramic production
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Prototype parts suitable for Government evaluation
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Clear roadmap for Phase II prototype hardware
This research directly supports:
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Navy undersea warfare modernization
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Supply chain resilience for critical sonar materials
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Enhanced sensor detection range (targeting significant acoustic performance gains)
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Dual-use commercialization opportunities in:
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Medical ultrasound
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Civilian sonar/navigation
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Infrastructure inspection
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Advanced aerospace ceramics
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Estimated 15–25 hours/week over 6 months
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Flexible scheduling with milestone-based deliverables
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Competitive project-based award commensurate with expertise, facilities access, and technical scope
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Potential continuation into larger Phase II and Phase III opportunities based on successful outcomes
A technically entrepreneurial researcher capable of bridging advanced materials science with practical manufacturing innovation, while supporting national defense modernization and future commercial transition.
