Job Description
Primary ObjectiveDevelop 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.Key ResponsibilitiesTechnical Research & DevelopmentDesign and formulate shear-thinning ceramic paste/slurry systems compatible with Navy piezoelectric ceramic materials.Develop robocasting or direct ink writing methods for consistent layer-by-layer extrusion and structural build-up.Investigate binder systems, solids loading, rheology, and nozzle geometries to optimize manufacturability.Evaluate methods to align high aspect ratio ceramic platelets during extrusion to create textured microstructures.Produce prototype samples in multiple geometries, including:Cylinders (~1 OD)Rings (>4 OD)Conduct or oversee binder burnout, sintering, densification, electrode application, and poling.Analysis, Modeling & ValidationModel material flow, particle alignment, and print dynamics to assess process feasibility.Characterize printed and sintered parts for:DensitySurface finishGrain/particle alignmentTexture fractionCapacitance (>200 pF target)Dielectric constantLoss tangent minimizationAcoustic and resonance performanceCompare additive-manufactured textured ceramics against traditional non-textured baselines.DeliverablesPhase I feasibility concept and technical approachInitial prototype geometries and performance dataRecommendations for Phase II hardware design specificationsFinal technical report summarizing:Material formulationManufacturing processPerformance outcomesRisks and transition recommendationsRequired QualificationsPhD (completed or ABD with strong publication record) in:Materials ScienceCeramic EngineeringMechanical EngineeringAdditive ManufacturingChemical EngineeringPhysics (materials-focused)Demonstrated expertise in one or more:Piezoelectric ceramicsRobocasting / Direct Ink WritingRheology of ceramic slurriesSintering and densificationMicrostructural characterizationFunctional ceramics or sonar materialsExperience with technical writing for SBIR/STTR, DoD, ONR, or Navy programs preferredFamiliarity with lead-based ceramics, textured ceramics, or anisotropic particulate systems strongly preferredPreferred SkillsCOMSOL, ANSYS, or similar modeling toolsSEM/XRD/EBSD or other microstructure analysis techniquesElectrical/acoustic characterization of piezoelectric materialsPrototype fabrication and laboratory scale-up planningTechnology transition strategy for defense or commercial sectorsExpected OutcomesBy the end of the six-month period, the awardee should demonstrate:Feasibility of a DIW/robocasting process for Navy piezoelectric ceramicsViable pathway to large-format textured ceramic productionPrototype parts suitable for Government evaluationClear roadmap for Phase II prototype hardwareStrategic ImpactThis research directly supports:Navy undersea warfare modernizationSupply chain resilience for critical sonar materialsEnhanced sensor detection range (targeting significant acoustic performance gains)Dual-use commercialization opportunities in:Medical ultrasoundCivilian sonar/navigationInfrastructure inspectionAdvanced aerospace ceramicsTime CommitmentEstimated 1525 hours/week over 6 monthsFlexible scheduling with milestone-based deliverablesCompensationCompetitive project-based award commensurate with expertise, facilities access, and technical scopePotential continuation into larger Phase II and Phase III opportunities based on successful outcomesIdeal Candidate ProfileA technically entrepreneurial researcher capable of bridging advanced materials science with practical manufacturing innovation, while supporting national defense modernization and future commercial transition. recblid 9bm2tqizggwwpo2yjaoll1yzluw3lb