Innovations in high-rate composite manufacturing: integrating additive manufacturing with compression molding process

Research output: Chapter in Book/Report/Conference proceedingChapterpeer-review

Abstract

Advanced composites play a pivotal role in modern engineering, offering exceptional strength-to-weight ratios and tailored properties, essential for various industries. High-rate composite manufacturing techniques have rapid production capabilities, which are essential for meeting the demands of industries requiring cost-saving, efficiency, and quick turnaround times. This chapter explores the Additive Manufacturing-Compression Molding (AM-CM) system developed by Oak Ridge National Laboratory (ORNL) for advanced composites manufacturing. The AM-CM system integrates additive manufacturing with compression molding, facilitating the production of polymer composite parts with superior mechanical properties and meticulously controlled microstructures. This innovative system not only ensures precise material deposition but also operates as a fast composite manufacturing process, enhancing productivity and performance, which are needed attributes across industrial applications. Through comprehensive mechanical testing and microstructural analysis, AM-CM promotes remarkable fiber alignment and reduced porosity in composite parts compared to alternative thermoplastic high-rate composite manufacturing methods. Furthermore, AM-CM enables overmolding reinforcement using continuous carbon fiber and supports selective reinforcement through customizable toolpaths. It also facilitates the production of hybrid materials to achieve tailored mechanical properties. Future advancements in AM-CM technology aim to enhance process efficiency, broaden material versatility, and improve part performance. This involves exploring novel materials, advancing process monitoring, implementing automation technologies, and integrating artificial intelligence (AI) and machine learning (ML) for predictive modeling and real-time optimization in composite manufacturing. These developments will establish the AM-CM system as a transformative technology in composite manufacturing, driving innovation across industries.

Original languageEnglish
Title of host publicationHybrid Composite Materials and Manufacturing
Subtitle of host publicationFibers, Nano-Fillers and Integrated Additive Processes
PublisherDe Gruyter
Pages115-138
Number of pages24
ISBN (Electronic)9783111019543
ISBN (Print)9783111019345
DOIs
StatePublished - Jan 1 2024

Keywords

  • advanced composites
  • AM-CM system
  • fiber alignment
  • high-rate manufacturing
  • mechanical properties
  • reduced porosity

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