I-Corps:Automated manufacturing of fiber-reinforced polymer composites

I-Corps项目更广泛的影响/商业潜力是开发纤维增强聚合物复合材料（frpc）的自动化制造。所提出的技术可用于开发具有成本效益的轻质FRPC部件，用于各种应用和行业，包括航空航天，能源，汽车和生物医学。传统的frpc制造依赖于昂贵的工具和模具，在烤箱和高压灭菌器中加热周期长，以及劳动密集型的过程，使得frpc的生产速度缓慢且成本过高。所提出的技术是一种先进的制造方法，基于使用机器人平台自动处理和放置复合材料，并在制造过程中快速固化材料。提出的制造方法允许快速，成本效益和节能的定制复合材料部件的生产。此外，提出的无模制造方法可以设计出传统方法无法生产的复杂复合结构。新的设计能力可能支持更轻的地面和空中交通工具的发展，以及更有效的能源转换的更大的风力涡轮机。I-Corps项目的基础是开发一种先进的制造平台，用于快速、自动化地制造高性能纤维增强聚合物复合材料。所提出的技术依赖于使用机器人平台将热固性树脂浸渍的碳纤维增强材料沿着所需的3D路径放置，然后对复合材料进行原位、瞬时固化和固化。控制材料的放置，以构建所需的结构，消除了对模具和工具的需要，通常用于复合材料工业。控制工艺参数允许制造具有低空隙含量和高浓度碳纤维增强的FRPC零件。此外，原位固化和固化复合材料的能力使其能够在半空中自由成形、无支撑制造，并实现三维增强。与传统方法相比，拟议的技术可能会减少能源消耗，从而实现更可持续的做法。该奖项反映了美国国家科学基金会的法定使命，并通过使用基金会的知识价值和更广泛的影响审查标准进行评估，被认为值得支持。

The broader impact/commercial potential of this I-Corps project is the development of automated manufacturing of fiber-reinforced polymer composites (FRPCs). The proposed technology may be used to develop cost-effective and lightweight FRPC parts for use in a wide variety of applications and industries including aerospace, energy, automotive, and biomedical. Traditional manufacturing of FRPCs relies on expensive tooling and molds, long heating cycles in ovens and autoclaves, and labor-intensive processes, making the production of FRPCs slow and cost prohibitive. The proposed technology is an advanced manufacturing method based on the automated handling and placement of composite materials using robotic platforms and rapid rigidization of the material during the manufacturing process. The proposed manufacturing method allows for rapid, cost-effective, and energy-efficient production of customized composite parts. In addition, the proposed mold-free manufacturing method enables the design of complex composite structures that cannot be produced using traditional approaches. The new design capabilities may support the development of lighter ground and aerial vehicles as well as larger wind turbines for more efficient energy conversion.This I-Corps project is based on the development of an advanced manufacturing platform for the rapid and automated manufacture of high-performance fiber-reinforced polymer composites. The proposed technology relies on the placement of carbon fiber reinforcements impregnated with a thermoset resin along desired 3D paths using a robotic platform followed by in-situ, instantaneous curing and rigidization of the composite material. Controlled placement of the material to construct the desired structure eliminates the need for molds and tooling commonly used in the composite industry. Controlling the process parameters allows for manufacture of FRPC parts with a low void content and high concentrations of carbon fiber reinforcements. In addition, the ability to cure in-situ and rigidize composites enables freeform, support-free manufacturing in midair and achievement of three-dimensional reinforcements. The proposed technology may cut down the energy use compared to traditional approaches, leading to more sustainable practices.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.