YIP Structural integration of hybrid electronic functionality on complex 3D surfaces
Abstract
This work will advance functionality of aerospace composite structures for naval applications by integrating electronics on curved three-dimensional (3D) parts. This will combine digital, conformal printing with hybrid electronics (conventional integrated circuits plus printed components) to enable reductions in size and weight, flexibility in form factor, and enhancement in functionality for naval aviation platforms and weapons systems. Digital, additive manufacturing methods are well suited for conformal patterning of electronically functional materials onto complex 3D surfaces. We have developed several unique tools to advance this capability, including an aerosol jet printing system mounted on a six-axis robotic arm, which allows fabrication of electronics with 20-50 micron precision, non-contact deposition to contour complex surface, and generalization to printing on both large, immobile surfaces and confined interior geometries. We also developed process planning tools to conformally wrap planar circuit designs onto doubly curved 3D parts, establishing a compelling capability for integrating hybrid electronic circuits, conformal antennas, and advanced shielding functionality. This will support reductions in size and weight for critical aviation and weapons platforms. Moving more advanced electronics to peripheral structures or confined spaces can support communication and radar systems, diverse sensing and health monitoring, tailored shielding for electronics protection, reduced weight of wiring, and higher payload, among other advantages. Demonstrating reliable hybrid electronic systems will expand design freedom for a wide range of applications. Aerosol jet printing is particularly attractive for this, as it has demonstrated utility for combining integrated circuits, discrete passive electronics, and antennas, with high interest among DoD labs and contractors. The fundamental challenges at the core of this project shape three primary research tasks. (1) Establish reliability for both the manufacturing process and device operational stability using unique process monitoring and control capabilities and an innovative hybrid interface design, respectively. (2) Expand computational tools to expedite conformal aerosol jet printing on complex surfaces, including intelligent motion planning tailored to the challenges of hybrid devices and doubly curved surfaces. (3) Benchmark performance and create demonstrators for hybrid electronics on aerospace composites using purpose-built motion platforms to target patterning on large, immobile objects as well as confined internal geometries, spanning materials selection, motion platform development, and postprocessing to achieve a robust interface and electrical performance. Demonstrator applications guided by stakeholder input could include conformal antennas (exemplar for 3D design tools), embedded frequency selective surfaces for electronics protection (exemplar for process reliability and control), and integrated microelectronics combining conventional semiconductors with printed antennas and interconnects (exemplar for hybrid integration of ICs).
Document Details
- Document Type
- DoD Grant Award
- Publication Date
- Feb 24, 2025
- Source ID
- N000142512134
Entities
People
- Ethan B Secor
Organizations
- Iowa State University
- Office of Naval Research
- United States Navy