Description: This NASA SBIR Phase I proposal presents an unprecedented laser additive manufacturing system for making Hall-effect thruster discharge channels, by using a pulsed fiber laser. It is the enabling technology for manufacturing desired density and repeatability. With our successful history in AM and SM processing, this proposal has a great potential to succeed. A proof of concept demonstration along with simulation will be carried out and samples will be delivered at the end of Phase 1. Prototypes in compliance with the discharge channel requirements will be delivered at the end of Phase II.

Benefits: In addition to NASA’s discharge channel manufacturing, the proposed pulsed laser AM process can also be used in other applications, such as space vehicle, aircraft, and satellite manufacturing. PolarOnyx will develop a series of products to meet various requirements for commercial/military deployments.

3D printing uses various technologies for building the products for all kinds of applications from foods, toys to rockets and cars. The global market for 3D Printing is projected to reach US$44 billion by the year 2025. Medical devices and biomedical instrumentation, consisting of surgical and infection control devices, general medical devices, cardiovascular, home healthcare, and other devices.