New Frontiers in Additive Manufacturing of Fiber Reinforced Composite
Abstract
Releasable Project Title: New Frontiers in Additive Manufacturing of Fiber-Reinforced Composites Principle Investigator: Dr. George Youssef, Professor of Mechanical Engineering Institution: San Diego State University Ð Department of Mechanical Engineering Research: Arguably, the manufacturing of fiber-reinforced polymer matrix composites is intrinsically additive since the structures are built from the ground up layer-by-layer. Nonetheless, composites manufacturing is a resources-intense process, often requiring exhaustive post-curing destructive and nondestructive characterizations to achieve desired confidence in the performance of mission-critical parts and components. Therefore, advanced manufacturing techniques, including robotics, can facilitate a substantial reduction in required resources while accelerating time to market and potentially in-operando nondestructive evaluation and characterization. This project aims to establish an additive manufacturing research hub at San Diego State University by acquiring an additive manufacturing robotics system for the fabrication of complex polymerbased and composites-based parts and components. The proposed system acquisition can manufacture large, real-life components (meter-scale) using a wide variety of materials, including fiber-reinforced composites) while allowing in-situ curing, eliminating many existing composite manufacturing shortcomings. The proposed system will supplement the existing capabilities while providing a path for the long-term goal of integrating terahertz-based nondestructive evaluation during the manufacturing process. Furthermore, the advanced manufacturing system will be used to train the next generation of scientists and engineers from underrepresented and underserved students, including women, military veterans, and their families. Equipment: Instilling experiential advanced manufacturing skills in the future generation of engineers and scientists requires producing large components, parts, and structures. The proposed advanced robotic composites manufacturing system is an exemplary research and education testbed, allowing the realization of real-size products while providing ample opportunity for experimentation and discovery. Versatility is an intrinsic hallmark of the proposed system (1) without limitations of the source or the type of materials (thermoplastic, thermosets, and fiberreinforced), (2) equipped with upgradable build-plate (1.2m?1.2m), (3) configurable with several robotic arms, (4) high-temperature extruder with varying filament diameters, and (5) flexible endeffector technology to enable interfacing with other pre- and post-manufacturing steps (finishing and nondestructive evaluation). Thus, the proposed system embodies the definition of an advanced manufacturing platform, encompassing advanced materials, robotics, experimentations, analyses, and characterization, with unprecedented opportunities to gain a fundamental understanding of large-scale additive manufacturing of composites. Furthermore, students are poised to receive revolutionary training given the uniqueness of the proposed since SDSU will be the first Western U.S.A. university to acquire this advanced robotic system. Research-related Education: The equipment will enhance the research infrastructure of SDSU, allowing the research team to enact its vision ÒAdvancing Mechanics and Broadening ParticipationÓ at a larger scale. Notably, our vision of scientific innovations and the deep engagement of students in research is full congruent with the objective of this funding mechanism. This, in turn, will provide additional research opportunities to students, which is also consistent with SDSUÕs culture and mission of providing: Òwell-balanced, high-quality education.Ó In addition, students will gain unprecedented insights into the mechanics of materials for advanced technologies. Specifically, unrepresentative and underserved students (i
Document Details
- Document Type
- DoD Grant Award
- Publication Date
- Aug 02, 2022
- Source ID
- W911NF2210199
Entities
People
- George Youssef
Organizations
- Army Contracting Command
- Office of the Secretary of Defense
- Salk Institute for Biological Studies