Aim Point Innovation LLC
SBIR Principal Investigator Robocasting Ceramic Sensors
Remote
·
Part time
Company website
We are seeking a highly qualified PhD-level researcher or materials scientist with expertise in ceramics, additive manufacturing, piezoelectric materials, or related disciplines to lead a six-month research initiative focused on developing an innovative, low-cost manufacturing process for large-format textured piezoelectric ceramics for next-generation undersea sensor systems. This role is designed as a part-time, project-based award supporting early-stage feasibility validation of robocasting/direct ink writing (DIW) processes for Navy-relevant piezoelectric ceramic applications. The selected awardee will investigate scalable manufacturing pathways capable of modernizing a legacy supplier base while enhancing acoustic and electrical sensor performance.
About Aim Point Innovation LLC
Description
Primary Objective
Develop 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 Responsibilities
Technical Research & Development
- Design 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 & Validation
- Model material flow, particle alignment, and print dynamics to assess process feasibility.
- Characterize printed and sintered parts for:
- Density
- Surface finish
- Grain/particle alignment
- Texture fraction
- Capacitance (>200 pF target)
- Dielectric constant
- Loss tangent minimization
- Acoustic and resonance performance
- Compare additive-manufactured textured ceramics against traditional non-textured baselines.
Deliverables
- Phase I feasibility concept and technical approach
- Initial prototype geometries and performance data
- Recommendations for Phase II hardware design specifications
- Final technical report summarizing:
- Material formulation
- Manufacturing process
- Performance outcomes
- Risks and transition recommendations
Required Qualifications
- PhD (completed or ABD with strong publication record) in:
- Materials Science
- Ceramic Engineering
- Mechanical Engineering
- Additive Manufacturing
- Chemical Engineering
- Physics (materials-focused)
- Demonstrated expertise in one or more:
- Piezoelectric ceramics
- Robocasting / Direct Ink Writing
- Rheology of ceramic slurries
- Sintering and densification
- Microstructural characterization
- Functional ceramics or sonar materials
- Experience with technical writing for SBIR/STTR, DoD, ONR, or Navy programs preferred
- Familiarity with lead-based ceramics, textured ceramics, or anisotropic particulate systems strongly preferred
Preferred Skills
- COMSOL, ANSYS, or similar modeling tools
- SEM/XRD/EBSD or other microstructure analysis techniques
- Electrical/acoustic characterization of piezoelectric materials
- Prototype fabrication and laboratory scale-up planning
- Technology transition strategy for defense or commercial sectors
Expected Outcomes
By the end of the six-month period, the awardee should demonstrate:
- Feasibility of a DIW/robocasting process for Navy piezoelectric ceramics
- Viable pathway to large-format textured ceramic production
- Prototype parts suitable for Government evaluation
- Clear roadmap for Phase II prototype hardware
Strategic Impact
This research directly supports:
- Navy undersea warfare modernization
- Supply chain resilience for critical sonar materials
- Enhanced sensor detection range (targeting significant acoustic performance gains)
- Dual-use commercialization opportunities in:
- Medical ultrasound
- Civilian sonar/navigation
- Infrastructure inspection
- Advanced aerospace ceramics
Time Commitment
- Estimated 15–25 hours/week over 6 months
- Flexible scheduling with milestone-based deliverables
Compensation
- Competitive project-based award commensurate with expertise, facilities access, and technical scope
- Potential continuation into larger Phase II and Phase III opportunities based on successful outcomes
Ideal Candidate Profile
A technically entrepreneurial researcher capable of bridging advanced materials science with practical manufacturing innovation, while supporting national defense modernization and future commercial transition.