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

这个i-Corps项目的更广泛的影响/商业潜力是纤维增强聚合物复合材料(FRPC)自动化制造的发展。建议的技术可用于开发成本效益高、重量轻的FRPC部件，用于包括航空航天、能源、汽车和生物医学在内的各种应用和行业。FRPC的传统制造依赖于昂贵的工具和模具、烤箱和高压锅的长加热周期以及劳动密集型工艺，使得FRPC的生产缓慢且成本高昂。拟议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，并在制造过程中对材料进行快速刚性处理。所提出的制造方法允许快速、低成本和高能效地生产定制的复合材料部件。此外，所提出的无模制造方法使得无法使用传统方法生产的复杂复合材料结构的设计成为可能。新的设计能力可能会支持更轻的地面和空中车辆以及更大的风力涡轮机的开发，以实现更高效的能源转换。这个i-Corps项目基于开发一个先进的制造平台，用于快速和自动化制造高性能纤维增强聚合物复合材料。这项拟议的技术依赖于使用机器人平台沿着所需的3D路径放置浸渍了热固性树脂的碳纤维增强材料，然后对复合材料进行原位、瞬时固化和硬化。控制材料的放置以构建所需的结构，消除了对复合材料行业中常用的模具和工具的需求。通过控制工艺参数，可以制造含气孔率低、碳纤维增强材料浓度高的FRPC零件。此外，原位固化和硬化复合材料的能力使其能够在半空中自由成型、无支架制造，并实现三维增强。与传统方法相比，建议的技术可能会减少能源消耗，导致更可持续的实践。这一奖项反映了NSF的法定使命，并通过使用基金会的智力优势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.