Our monthly webinar series “Innovation Insights” continued Monday, March 17, as IACMI EVP/CCO Dale Brosius moderated discussions on recent technology advancements from IACMI members.
We heard from:
Dr. Harsh Baid – Chief Scientist
Dr. Saratchandra (Sarat) Kundurthi – Research Scientist
Mallikharjun (Arjun) Marrey- Additive Engineer
Co-presenting from AlphaSTAR
Build Simulation and Experimental Study of Large-Format Additive Manufacturing of Thermoplastic Polymer Composites
Large-Format Additive Manufacturing (LFAM) is emerging as a transformative technology with considerable potential across multiple sectors, provided that key implementation challenges are effectively addressed. Traditional trial-and-error methods are not practical due to their high costs and limited success in tackling the unique issues associated with LFAM, such as precise control of temperature and layer time, as well as problems related to layer adhesion, warping, and delamination. This study introduces a physics-based Integrated Computational Materials Engineering (ICME) approach for LFAM, supported by a comprehensive case study. The simulation framework incorporates micro-mechanics-based material modeling to characterize temperature-dependent mechanical properties, along with thermal analysis driven by machine GCode to accurately forecast temperature distribution during the printing process. This allows for the identification of optimal layer time parameters for recoating, enhancing layer adhesion and minimizing defects. Additionally, mechanical analysis considers the raft and part clamping mechanisms during printing to identify issues such as warping, delamination, and Z-stress accumulation. The case study demonstrates the effectiveness of this simulation methodology through the fabrication of a large custom geometry using chopped fiber filled polymer material system. The study not only highlights potential defects linked to the GCode but also identifies design features susceptible to high-stress concentrations and localized failures. Overall, this research underscores the critical role of physics-based simulations in addressing the inherent challenges of LFAM, facilitating informed decision-making, and accelerating technology adoption.
Dr. Pierre-Yves Mechin
Composites R&D Director
Dassault Systemes
Materials Multiscale Modeling by Dassault Systemes
Materials used in the manufacturing industry all exhibit microstructure which depends on the manufacturing process and the life cycle of the raw matter used.
A multiscale approach is required to establish a link between the molecular scale (atomic level) and effective margin of safety in design, which is possible thanks to multiscale modelling & simulation where exploration of variable materials arrangements is critical.
AI technologies and generative design make possible the exploration of various manufactured products that are optimized thanks to existing or innovative materials.
Parametric definitions of many microstructures are used to explore material variability and compare experimental results & virtual twins of composites materials, and multiscale analysis is proposed as an engineering solution to understand the failure mechanisms of materials & structures.
Vipin Kumar, Ph.D.
R&D Staff Member, Composites Innovation Group
Oak Ridge National Laboratory
Lightning Strike Protection of Wind-Turbine Blades: State-of-the-art and Future Trends
The rapid expansion of the wind energy industry, particularly with U.S. offshore wind energy production targets of 30 GW by 2030, necessitates robust lightning strike protection (LSP) systems for Glass Fiber Reinforced Polymer (GFRP) and Carbon Fiber Reinforced Polymer (CFRP) composites used in wind turbine blades. These materials’ low electrical conductivity makes them vulnerable to catastrophic lightning damage. Current LSP solutions, such as metallic arrestors and diverter strips, are either limited in effectiveness or prohibitively expensive for full blade coverage. This presentation explores a novel approach using electrically conductive polymeric coatings, which are cost-effective, easy to apply, and compatible with automated manufacturing processes. Experimental results demonstrate that these coatings effectively dissipate electrical currents and protect composite structures from lightning-induced damage, offering a promising alternative to traditional metallic LSP systems for the wind energy industry.
