Nick Meisel (nam20@psu.edu), Sven Bilén (sbilen@psu.edu) Creation of Multi-Functional Structures via Embedding in Additive Manufacturing Nick Meisel (nam20@psu.edu), Sven Bilén (sbilen@psu.edu) Combining AM with embedding can lead to strong, “smart parts” directly from the build tray Identify candidate elements (e.g., antennas, wiring, sensors) for embedding with CFRP AM Identify geometric similarities between candidates and determine appropriate embedding tools and process modifications Evaluate impact of embedding process parameters on component performance and part properties Length of project: 10-12 months Resources: $70,000 for 1 student, faculty members, and supplies, materials, and equipment Many traditionally manufactured and assembled products have elements of multi-functionality within them. Design rules and process steps for robust AM embedding creates new avenues for complex, small batch, and customized multifunctional products Task #   Month: 1 2 3 4 5 6 7 8 9 10 11 12 Task 1: Identification of candidate parts / components of interest Task 2: Identification of embedding geometries and process chain Task 3: Investigate tools to integrate multi-material element with printed part Task 4: Measurement of geometric parameter impact on embedding quality Task 5: Verification of embedded prototype mechanical properties Task 6: Verification of prototype compatibility with the intended environment Practical design ruleset to guide the embedding of multifunctional electronic components in carbon fiber reinforced printed parts Detailed process flow capable of guiding users through embedding process to reduce user risk and improve probability of embedding success Method for verifying embedded component functionality and evaluating printed part quality New Design Paradigms and Processes Specialized AM systems are capable of depositing elements of multi-functionality or strength, including Voxel8 and MarkForged, but provide no guidance for proper design Universities have begun to develop custom research-oriented systems capable of creating multifunctional products, but are not easily acquired by industry 2 – Concept Formulated 5 – Key Elements Demonstrated Proposed 0% Lopes et. al. 2012 Embedding techniques can circumvent material limitations in AM to make multifunctional structures, but tend to be limited to polymer processes Joining electronic embedding with carbon fiber reinforced polymer (CFRP) printing can produce multifunctional structures with desirable mechanical properties However, embedding rules and impacts on part properties are not well understood Use of embedding on low-cost consumer grade machines eliminates need for custom-built systems Emphasis on developing practical, useable design rules helps to guide embedding across products and contexts Validation of part properties when embedding occurs has been neglected in existing research Electrical/Thermal Conductivity Sensing and Actuation Energy Harvesting and Storage Structural Health Monitoring Electromagnetic Shielding