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Company
Portfolio Data
Back to Company SearchRE3D, INC.
UEI: W6N4D7JMXA35
Number of Employees: 27
HUBZone Owned: No
Woman Owned: Yes
Socially and Economically Disadvantaged: Yes
SBIR/STTR Involvement
Year of first award: 2018
6
Phase I Awards
7
Phase II Awards
116.67%
Conversion Rate
$648,118
Phase I Dollars
$7,450,769
Phase II Dollars
$8,098,887
Total Awarded
Awards
3D Printing Army Supplies Directly From Discarded Plastic Waste
Amount: $1,999,506 Topic: A224-016
The US military has recognized additive manufacturing (AM) as a critical technology to promote design innovation, mission resilience and warfighter readiness.Ā AM systems and processes which utilize local waste as material input provide added value in austere or contested environments where supply chains may be compromised.Ā Recycling and material recovery also provide long-term value to the DoD by supporting waste mitigation and sustainability initiatives.Ā During a US Army SBIR Direct-to-Phase II effort (Contract W51701-22-C-0122), re:3D Inc developed a containerized mobile recycling facility which utilizes the GigabotX 2, a fused granular fabrication (FGF) 3D printer designed, commercialized and manufactured by the company.Ā These ōGigalabsö contain the equipment required to process thermoplastic waste into feedstock and, via additive manufacturing, fabricate articles of use at the point of need. The progression of this technology into widespread acceptance and adoption by the DoD, other federal agencies and commercial interests requires advancements in print speed, print volume and mixed-waste processing.Ā This proposal for SBIR Phase II Sequential funding lays a path to develop improved AM extrusion hardware, provide for printing with mixed plastics, and allow the recovery of non-polymer waste by incorporating biomaterials into the feedstock to improve part performance.Ā re:3D will leverage its expertise in manufacturing, hardware development and the use of recyclates in additive manufacturing processes with contributions from polymer science and additive manufacturing experts at the University of Massachusetts Lowell and the University of Maine. This collaboration will result in printing bigger and faster, using a wider range of recycled waste materials.
Tagged as:
SBIR
Phase II
2024
DOD
ARMY
3D Printing of High Temperature Thermoset Foams for Space Vehicular Thermal Protection Systems
Amount: $746,379 Topic: T12
nbsp;Based on the knowledge and expertise gained in partnership with the University of Tennessee at Knoxville (UTK) during the NASA/STTR Phase I work, re:3D proposes the development of a pilot system for the deposition of a phenolic foam TPS surface onto a scaled demonstration article in parallel with refinements and improvements to the foamrsquo;s material characteristics.The Phase II research activities at UTK will focus on understanding the processing requirements to scale up production of the foam feedstock to 3D print large-scale test articles, refine the foam to further lower density and increase temperature stability, explore novel printing approaches to tailor effective density and elastic modulus and/or incorporate graded composition to raise temperature stability at the outer surface, and continued plasma arc jet torch testing of the developed materials and architectures.During Phase II, re:3D will be responsible for designing, developing and building the systems and mechanisms required for a pilot material extrusion system of the phenolic foam onto a scaled demonstration article consisting of an aluminum dome with a radius of curvature of approximately 1 meter and a 1-meter base diameter.nbsp; The system would be comprised of the following elements:Mixing of the foam components, either outsourced or performed in-house as determined by a feasibility study during the course of the Phase II investigation at UTKTransport of the foam from the mixing containers to the deposition nozzle through the use of an appropriate metering pumpConformal deposition of the foam onto the aluminum dome with in-situ defect monitoring and advanced motion planning using a gantry printer based on re:3Drsquo;s existing Terabot platform and a custom-designed extruder with added degrees of motionCuring of the foam in an appropriate industrial ovenPost-process machining to achieve the final desired finish of the TPS surface
Tagged as:
STTR
Phase II
2023
NASA
On-Orbit Additive Manufacturing Using Recycled Waste
Amount: $811,046 Topic: 5-Recyc
re:3D Inc. proposes to build a functional benchtop demonstration unit of an integrated waste-to-print recycling system based on a granulation mechanism and 3D printer capacble of turning thermoplastic waste generated from logistics foam available from in-space applications into functional and useful objects through the use of material extrusion additive manufacturing (AM).This will be a low size, weight and power (SWaP) engineering prototype based on re:3D's commercial Gigabot X (GBX) technology and new innovative methods to shred the bulk foam and transport the resulting loose granulate in a contained system.The design will address the unique challenges of operating in microgravity with limited space and power resources.
Tagged as:
SBIR
Phase II
2023
NASA
On-Orbit Additive Manufacturing Using Recycled Waste
Amount: $141,658 Topic: 5-Recyc
re:3D Inc. proposes developing a recycling system centered on a 3D printer capable of turning thermoplastic waste generated on orbit into functional and useful objects through the use of material extrusion additive manufacturing (AM).Guided by the analysis of available on-orbit waste streams and their potential printability, a low size, weight and power (SWaP) engineering prototype printer, based on re:3D's Gigabot X (GBX) technology, will be designed and demonstrated. The GBX is a commercial printer capable of printing directly from ground plastic flakes. Printing from flake eliminates the need for the extra space, resources and energy required for an intermediate step of producing filament - the most common approach to recycling plastics for 3D printing. In addition to the prototype printer demonstration, re:3D will deliver the engineering specifications for a low-SWaP integrated recycling system to include waste granulation and other required steps in the waste-to-print AM process.
Tagged as:
SBIR
Phase I
2023
NASA
Creating Value from Base Waste with Translation to Austere Environments: 3D Printing in Mobile Recycling Facilities
Amount: $749,999 Topic: AF211-CSO1
Contested environments present unique challenges for maintaining equipment or prototyping on-demand solutions. Resource scarcity and regional considerations must be anticipated in advance in order to ensure that all necessary materials are forward deployed. Operational missions can be further complicated by potentially unpredictable resupply of essential materials and equipment. Consequently, excessive amounts of costly on-demand inventory often must be pre-positioned in case of aging equipment failure or compromised reserve replenishment. These considerations can constrain innovative autonomy, increase supply chain costs and delay fulfilling mission objectives. Recent manufacturing advancements offer potential locally-based alternatives to reduce the dependence on materials and equipment imported into theater using 3D-printing. However, the ability to produce functional 3D-prints is contingent on access to input materials, which can degrade over time. Specifically, the ability to source locally available raw material and feed it directly into a printer could be extremely advantageous for the warfighter by eliminating logistics of importing & storing extruded filament. Furthermore, the ability to use plastic waste as a feedstock has the added benefit of reducing supply chain costs, achieving sustainability goals, and increasing readiness. The benefits of this innovation are amplified when 3D-printing large-scale industrial objects (defined as > 18 inches cubed) as the production of large-scale products represents a larger investment of time and material costs (pellets/flake are ~ 1/10th the cost of filament and can print faster). With domain expertise in large-scale 3D-printing, re:3D has developed a 3D printer capable of printing with virgin or recycled pellets and flake. Plastic waste sourced for DAF bases has been tested for 3D-printing feasibility & multiple requests for objects that can have DAF value have been received across CONUS. Potential DAF users of this hardware have requested packaging all the equipment that supports 3D-printing from waste in an off-grid container. During this award, re:3D proposes to further analyze the plastic waste created at USAFA, and adjust the hardware needed to enable a system that supports the collection, processing & 3D-printing of functional parts of DAF value directly from plastic trash in two containerized 3D-printing Mobile Recycling Facilities (MRF’s) powered by off-grid power. Curriculum will be developed for USAFA faculty & cadets to support operations, maintenance & training upon installation at the he Field Engineering and Readiness Laboratory(FERL).
Tagged as:
SBIR
Phase II
2022
DOD
USAF
Off Grid 3D Printing of Army Supplies Directly From Discarded Plastic Waste
Amount: $1,695,478 Topic: A224-016
Redacted
Tagged as:
SBIR
Phase II
2022
DOD
ARMY
3D Printing of High Temperature Thermoset Foams for Space Vehicular Thermal Protection Systems
Amount: $124,911 Topic: T12
We propose to create an open-source modification of our commercially available, affordable, industrial 3D printer, and in conjunction develop printable, high temperature hybrid thermosetnbsp;(HT2) materials in partnership with the University of Tennessee at Knoxville (UTK) during this Phase 1 NASA/STTR.In addition to additive manufacturingrsquo;s (AM) benefits of low-cost prototyping, efficient low volume manufacturing, and unparalleled ability to create complex geometries, utilizing the Gigabot platform offers scalability as research progresses to enable affordable and large-scale printing of TPS. The methodology proposed will have the potential of expanding the thermoset extrusion material library and significantly decrease the time spent on previous TPS systems.In collaboration between re:3D and UTK, HT2 Materials will be developed, and 3D printed with the target application of TPS for space vehicles. The TPS materials and methods will allow for optimum performance of extreme materials, making it possible to print them in more complex and contoured geometries to enable maximum heat shielding performance in space vehicular applications in launch and recovery. nbsp;This will involve the formulation of a three-phase, low-density, epoxy-polysilazane based syntactic foam, including high-alumina cenospheres and nanoclay reinforcement. The optimum material formulation will be paired with the CNC controlled movement of an extrusion head to enable tailored density and porosity control coupled with long pot life and several curing options to meet post-processing constraints. Various geometries will then be tested to demonstrate the optimized 3D printing parameters and resolution. The various parts that will be designed and fabricated will then be tested for their thermo-mechanical properties, extreme heat and flame resistance, and charring and ablation properties.
Tagged as:
STTR
Phase I
2021
NASA
Creating Value from Base Waste with Translation to Austere Environments: 3D Printing in Mobile Recycling Facilities
Amount: $36,000 Topic: AF211-CSO1
Contested environments present unique challenges for maintaining equipment or prototyping on-demand solutions in Air Force operations. Resource scarcity and regional considerations must be anticipated in advance in order to ensure that all necessary materials are forward deployed. Operational missions can be further complicated by potentially unpredictable resupply of essential materials and equipment. Consequently, excessive amounts of costly on-demand inventory often must be pre-positioned in case of aging equipment failure or compromised reserve replenishment. These considerations can constrain innovative autonomy, increase supply chain costs and delay fulfilling mission objectives. Recent manufacturing advancements offer potential locally-based alternatives to reduce the dependence on materials and equipment otherwise imported into theater using 3D printing. However, the ability to produce functional 3D prints is contingent on access to input materials, which can degrade over time. Specifically, the ability to source locally available raw material and feed it directly as pellets or shavings/flake into a printer rather than extruded filament could be extremely advantageous for the warfighter by reducing cost and increasing capabilities in prototyping and on demand fabrication. Further, the ability to use plastic waste as a feedstock has the added benefit of reducing supply chain costs, achieving sustainability goals, and allowing plastic waste to become a useful by-product of innovation. The benefits of this innovation are amplified when 3D printing large-scale industrial objects (defined as > 18 inches cubed). First, the production of large-scale products represents a larger investment of time and material costs (pellets are ~ 1/10th the cost of filament). A second reason for the importance of pellet extrusion is the ability to print significantly faster. With domain expertise in large-scale 3D printing, re:3D has developed a pellet extrusion 3D printer capable of printing with pellets and able to accept reclaimed flake as well as non-uniform pellets. This effort includes developing the ability to consistently dry and to easily clean and switch between materials. A novel mechanism for feeding larger volumes of pellets and/or flake into the platform is also being developed with the requisite controls as well as a desktop grinding system. Possible AF users of this hardware have expressed interest packaging this equipment in footprint optimized for DoD benefit. This award would allow for the opportunity to customize a full suite of hardware to enable the processing of waste for 3D printing. Specifally, re:3D proposes to analyze the plastic waste created at USAFA, to determine which of those plastics can be printed, and to created a system to allow for the printing of parts, drones and other items directly from trash in a containerized 3D printing Mobile Recycling Facility (MRF).
Tagged as:
SBIR
Phase I
2021
DOD
USAF
SBIR Phase II: Increasing Maker Manufacturing through 3D Printing with Reclaimed Plastic & Direct Drive Pellet Extrusion
Amount: $749,111 Topic: MN
Fused Filament Fabrication (FFF) offers tremendous benefit for rapid prototyping, mass customization, and low cost fabrication. This creates an untapped opportunity to develop the technology further to support low volume industrial manufacturing for price sensitive and emerging markets. The ability to source locally available raw material and feed it directly as pellets or shavings into a printer rather than extruded filament is extremely advantageous for both manufacturer and end user in regards to reducing cost and increasing capabilities in prototyping. The benefits of this innovation is amplified when 3D printing large-scale industrial objects (defined as > 18 inches cubed). First, the production of large-scale products represent a larger investment of time and material costs (pellets are ~ 1/10th the cost of filament). A second reason for the importance of pellet extrusion is it addresses the need to print faster. Finally, a dependence on extruded thermoform plastics limits the available library for printing and the ability to mix materials to engineer new formulations. With domain expertise in large-scale 3D FFF printing, re:3D proposes to evolve a prototype pellet 3D printer developed under Phase I to be able to address all of these needs by coupling direct drive pellet extrusion technology with a grinder, dryer and feeding system optimized for reclaimed plastics. re:3D intends to leverage Phase I research conducted on material requirements for polyethylene terephthalate (PET) and polypropylene (PP), two of the most available reclaimed plastics worldwide, to further optimize the pellet printer to be able to accept reclaimed flake as well as non uniform pellets. This effort will include developing the ability to consistently dry the input materials and to easily clean and switch between materials. A novel mechanism for feeding larger volumes of pellets and/or flake into the platform will also be developed with the requisite controls. Once complete, the company will pilot the solution in Texas through IC2 as well as in Puerto Rico, an island territory with a complicated supply chain, in conjunction with waste streams/partners identified by the Puerto Rico Science & Research Trust. The new hardware integration solutions developed in Phase 2 will be incorporated into the Phase I prototype platform which leveraged Michigan Technological University's (MTU) prior work conducting validation and materials testing in Phase I, prior work modifying direct drive recyclebots for FFF 3D printers, and open source firmware and software research. To ensure excellence, prototypes will be extensively tested using MTU's facilities with reclaimed PP and PET in prints to be used for casting, mold production and load bearing applications. Once the prototype design for commercial scalability has been validated at MTU and field-tested, all progress will be openly documented and shared in an effort to scale the solution suite to multiple platforms as quickly as possible. The hardware will be sold commercially after completing the project as both an integrated 3D printing solution and also as independent hardware due to the potential to be applied beyond Cartesian 3D printing systems. This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.
Tagged as:
SBIR
Phase II
2019
NSF
Large Scale 3D Printing Training Solutions to Address Air Force Stakeholder Needs
Amount: $699,250 Topic: AF191-004
Additive manufacturing offers tremendous benefit for rapid prototyping, mass customization, and low-cost fabrication. However, for defense & aerospace components, field-ready solutions are dependent on material choice & optimum print settings that maximize the potential for durability & functionality. 3D printing is not easy. To reliably obtain quality parts from this manufacturing process, the operator must have a thorough understanding of the technology. Additionally, many 3D printers are not large enough to produce functional prints using industrial-strength materials, nor are they affordable or easily deployable. Consequently, without accessible hardware that can accept a broad range of materials & consultation to provide training & print optimization, many defense applications are restricted to either traditional manufacturing methods, or oversized and cost prohibitive platforms that are not easily deployable. This can result in significant time and material loss, negating the value of rapid prototyping. Multiple re:3D customers have begun printing training aids to reduce costs and increase accessibility, however lacking 3D printing experience, the prints are less than optimum, and the user must spend hours redesigning the print and profile for each application.
Tagged as:
SBIR
Phase II
2019
DOD
USAF