Polyimide aerogels are a nanoporous material made by extracting the liquid portion of a wet gel and replacing it with air, while still maintaining the porous solid internal architecture. This results in a material with extremely low densities, low thermal conductivities, high internal surfaces areas, and low dielectric constants. Currently, complex aerogel forms are not possible, since they require molds in order to be shaped. To overcome this challenge, we are attempting to use various additive manufacturing techniques to produce complex architectures. Three different approaches are being studied to accomplish this. One is to print using a viscous wet gel and have the structure solidify at the end of the print, another is to use a mixing tip, where a less viscous gel and the final chemical that causes gelation will be mixed as it is printing, allowing it to gel layer by layer, and the third is to use a UV curable aerogel with a UV light following behind to solidify the gel as it prints. To have these approaches be successful, the printing parameters and the aerogel's chemical formulation need to be optimized. The more harmonious these two factors can be made, the more defined and complex the resulting structure can be. Preliminary results show that 3D printing polyimide aerogels are a viable option, but further optimization must occur for reliable printing.
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