I-Corps: Translation Potential of a Powder Spreadability Testing Device for Additive Manufacturing

NSF Award Search · 01002526DB NSF RESEARCH & RELATED ACTIVIT · $50,000 · view on nsf.gov ↗

Abstract

This I-Corps project focuses on the development of an accurate and precise quality control testing device for evaluating and approving powdered materials, referred to as qualifying feedstock powders, used in powder-based additive manufacturing (AM). The quality of the AM printed components depends on the quality of the powders that feed into the AM machine. If not closely monitored and controlled these powders can cause manufacturing defects. Qualifying feedstock powders is critical to ensuring repeatability, part quality, and performance, especially in industries like aerospace, medical device, and automotive, where safety and performance standards are strict. This solution provides a powder spreadability testing device that addresses this challenge. The adoption of this device has the potential to increase product quality and consistency, reduce machine downtime, reduce powder waste, and shorten the development cycle for powder bed-based additive manufacturing. This I-Corps project utilizes experiential learning coupled with a first-hand investigation of the industry ecosystem to assess the translation potential of the technology. This solution is based on the development of a testing device that can accurately test and quantify the spreadability of feedstock powders for powder bed-based additive manufacturing processes. The powder testing methods currently used in the additive manufacturing industry test the flow behavior of powders as bulk assemblies, meaning that the

Key facts

NSF award ID
2521047
Awardee
University of Wisconsin-Madison (WI)
SAM.gov UEI
LCLSJAGTNZQ7
PI
Lianyi Chen
Primary program
01002526DB NSF RESEARCH & RELATED ACTIVIT
All programs
Materials Engineering
Estimated total
$50,000
Funds obligated
$50,000
Transaction type
Standard Grant
Period
07/01/2025 → 06/30/2026