Multi-physics modeling and topology optimization for metal coated polymer structures

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As global manufacturing output continues to rise, industry is continually striving for increasing efficiency of production while simultaneously balancing the reduction of waste and emissions, typically under the directive of government regulations. Recent examples of minimizing the use of raw materials while maintaining favorable mechanical performance can be seen in the fields of metal coated polymers (MCPs). The advantages of incorporating MCPs into the manufacturing industry are widespread, including directly reducing emissions associated with shipping, increased product lifespan compared to conventional plastic components, and reliability for mission critical applications, where reduced weight and maximum stiffness are imperative. The proposed work is comprised of two interconnected research endeavors that share the mutual goal of increasing the ease of implementation of MCP technology into existing design practices. Firstly, creating accurate multi-physics modelling methods to be able to predict the complex behavior of MCP materials will allow designers to computationally test the performance of proposed designs. significantly reducing the number of physical prototypes required for component validation. The second goal of this research is to develop advanced design methodologies for the manufacturing of MCP products, including but not limited to MCP topology optimization and developing the process of the redesign of metal components for use with MCPs. The partnership will feature a three-year project, with three full-time graduate students and several on-site internships at General Dynamics Mission Systems.