Kyle T. Sullivan

Controlling Material Reactivity Using Architecture.

3D-printing methods are used to generate reactive material architectures. Several geometric parameters are observed to influence the resultant flame propagation velocity, indicating that the architecture can be utilized to control reactivity. Two different architectures, channels and hurdles, are generated, and thin films of thermite are deposited onto the surface. The architecture offers an additional route to control, at will, the energy release rate in reactive composite materials.

Additive Micro-Manufacturing of Designer Materials

Material properties are governed by the chemical composition and spatial arrangement of constituent elements at multiple length scales. This fundamentally limits material properties with respect to each other creating trade-offs when selecting materials for a specific application. For example, strength and density are inherently linked so that, in general, the more dense the material, the stronger it is in bulk form. Other coupled material properties include thermal expansion and thermal conductivity, hardness and fracture toughness, strength and thermal expansion, etc. We are combining advanced microstructural design, using flexure and screw theory as well as topology optimization, with new additive micro- and nano-manufacturing techniques to create new material systems with previously unachievable property combinations. Our manufacturing techniques include Projection Microstereolithography (PμSL), Direct Ink Writing (DIW), and Electrophoretic Deposition (EPD). These processes are capable of reliably producing designed architectures that are highly three-dimensional, multi-scale, and often composed of multiple constituent materials.