Extensive use of Unmanned Underwater Vehicles (UUVs) and remote equipment in future Naval operations leads to an energy logistics challenge for their rechargeable batteries. A solution to this challenge is a distributed network of renewable power sources detached from mainland power grids. One potential solution is Benthic Microbial Fuel Cell (BMFC) devices. BMFCs must be optimized and upscaled to produce power at relevant scales. 3-D printing is a promising manufacturing method to achieve scalable BMFC devices.
In this thesis, we devised, developed, and optimized a protocol for clearance of microfluidic channels using square cross-sections embedded within PolyJet 3-D-printed chips. The developed protocol demonstrated 75% volumetric clearance of the embedded channels. The protocol was then used to clear channels with T-shaped cross-sections, which were used to produce an experimental proof of principle for self-assembled wiring within the microchannels due to fluidic surface tension. These advancements have opened the door to embedded wiring for 3-D printed biofuel cells and other microfluidic technologies. When perfected and manufactured at scale, biofuel cells could provide a solution to the critical logistics problem of recharging UUVs and similar equipment employed in remote maritime environments, thereby making an exceptional contribution to the U.S. Navy, U.S. national security, and the related research fields.Office of Naval Research, Arlington, VA 22203Lieutenant, United States NavyApproved for public release. Distribution is unlimited
