Robocasting Ceramic Sensors

This SBIR topic, DON26BZ01-NV021, aims to develop a low-cost, flexible manufacturing technique for large format textured piezoelectric ceramics for undersea sensor applications. Current manufacturing processes for these critical components face challenges due to a shrinking supplier base, a shift away from lead-based products, and outdated technology. The primary objective is to validate the feasibility of integrating Navy piezoelectric ceramics with a robocasting or direct ink writing slurry system to produce textured ceramics with enhanced electrical and acoustic performance. This involves demonstrating consistent extrusion, proper layer adhesion, high solids loading, and successful sintering. A secondary focus is on aligning high aspect ratio ceramic platelets during the printing process to achieve improved piezoelectric properties. Phase I will involve concept development and feasibility demonstration, while Phase II will focus on prototype hardware development and delivery. Phase III will assist in transitioning the technology to Navy use, optimizing production, and exploring dual-use applications in medical imaging, civilian watercraft, and other military sensors like hypersonic radomes.