1. Nick Meisel (nam20@psu.edu), Sven Bilén (sbilen@psu.edu)
Creation of Multi-Functional Structures via Embedding in Additive Manufacturing
Nick Meisel Sven Bilén
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: 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