SBIR Principal Investigator Robocasting Ceramic Sensors

Project-Based Principal Investigator (PI)

Robocasting Ceramic Sensors – DON26BZ01-NV021

Period of Performance: 6 Months (Fall 2026 – Spring 2027)
Engagement Type: Part-Time (Project Award / Research Contract)
Location: Hybrid / Remote with periodic laboratory access as required
Funding Structure: Fixed-term SBIR Phase I-style research award

Position Overview

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.

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.