Objective

This topic seeks to develop open-source machine controller software and custom 3D printing toolheads that enable the fabrication and repair of printed circuit boards (PCBs). The goal is to adapt an existing 3D printer (commercial off-the-shelf (COTS) or custom built) with open-source software to support PCB printing capabilities, while also developing modular toolheads optimized for conductive material printing and circuit repair. Small businesses responding to this topic should select or develop a 3D printer that supports an open-source software configuration and modify that software to meet the specific needs of PCB fabrication. Prusa’s 3D printer suite serves as an example of a COTS system that is open-source and allows for custom toolheads, but its use is not required. Companies may choose to work with any 3D printer that fits the open-source requirement or, if necessary, develop a new system. The key focus is ensuring an open, adaptable ecosystem where software and hardware work together to enable PCB printing.

Description

The awarded company will develop:

1. Open-source machine controller software modifications that enhance an existing open-source 3D printer to support PCB fabrication and repair.
2. Custom toolheads that enable functionalities such as conductive ink printing, pick-and-place operations, and multi-layer PCB production.

Ideally, the solution should support key functionalities, including:

• Integration with a confocal scanner for substrate mapping and quality assurance.
• Automated detection and repair of conductive printed traces.
• Two methods of first-layer substrate detection to ensure precision.
• Point-to-point manual circuit repair capability for user intervention.
• Substrate alignment and automated path detection for multi-layer PCB fabrication.
• CAD/CAM workflow visualization to streamline design iteration and printing processes.
• The ability to project scanned height maps onto a conformal surface for accurate PCB production.
• Pick-and-place component alignment that automatically adjusts to the substrate.
• The ability to switch between the developed machine controller software and an OEM controller, ensuring flexibility in usage.

This solution must be built within an open-source framework, ensuring adaptability and future development. The key requirement is that the system leverages open-source software and includes custom toolheads designed for PCB manufacturing and repair.

Phase I

This topic is accepting Phase I proposals for a cost up to $250,000 for a six month period of performance.

To establish the feasibility of adapting open-source 3D printing systems for PCB fabrication and repair, the Phase I effort will focus on evaluating candidate COTS or custom-built 3D printers that support open-source machine controller software, conducting a technical assessment of integration pathways for multi-functional toolheads, and developing initial software modules to demonstrate control over basic PCB-relevant operations. Deliverables will include a technical feasibility report outlining the selected hardware platform and its suitability for modular toolhead integration, proof-of-concept demonstrations of software-driven motion control adapted for PCB deposition processes, and conceptual designs for toolheads enabling conductive ink deposition and pick-and-place functions. The Phase I work will also include preliminary software architecture documentation, risk analysis for multi-layer PCB printing integration, and an open-source compliance assessment to ensure future scalability. This foundation will validate the technical and operational viability of the proposed system and inform detailed engineering in Phase II.

Phase II

The outcome of this SBIR will be the ability to rapidly design/repair/replace obsolete components to combat obsolescence issues and meet mission objectives as well as provide custom stopgap solutions to an already fragile electronics supply chain. This effort relies heavily on machine controller software development for a specific use case.

Machine controller software exists for similar types of machines, maybe not all of the functionality that is being asked for, however, even though the software is mature, it will need to be tailored and proven to work on the AvMC inhouse machine so development work will be needed.

Phase III Dual Use Applications

This technology development could be tailored to be a machine agnostic controller software able to realize the potential of many printed microelectronics machines.

Submission Information

For more information, and to submit your full proposal package, visit the DSIP Portal.

View the SBIR Component Instructions. View the STTR Component Instructions.

SBIR|STTR Help Desk: usarmy.sbirsttr@army.mil