2023 R&D 100 Award for Precise, Continuous, & High-Speed Manufacturing of Thermoplastic Composites Using Additive Manufacturing-Compression Molding, AM-CM

Researchers at ORNL have created a highly automated process for thermoplastic composite manufacturing that combines the benefits of additive manufacturing, or AM, and compression molding, or CM, to produce a high-performance functional composite structure at automotive production rates.

The AM-CM process combines the best attributes of conventional processes to produce composite parts. AM deposits reinforced polymers, in which fibers are uniformly dispersed and oriented in the optimal direction, and CM removes voids while imparting a smooth finish.

This process addresses shortcomings in existing advanced additive and traditional processes while retaining their desirable features and has the potential to become a dominant manufacturing process for polymers and composites.

DOE’s Office of Energy Efficiency and Renewable Energy, Advanced Materials and Manufacturing Technologies Office (AMMTO) provided funding for this research.

Development was led by ORNL’s Vipin Kumar with ORNL’s Vlastimil Kunc, Ahmed Hassen, David Nuttall, Seokpum Kim, Deepak Kumar Pokkalla, Paritosh Mhatre, Bill Peter, Craig Blue and Joshua Vaughan assisting in development.