Additive manufacturing of composite lattice and shell structures for lightweight applications

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Additive manufacturing (AM) is a rapidly developing technology in which products are built up by depositing material where it is needed. This contrasts conventional manufacturing processes, like machining or casting, where material is removed or there is a high dependency on expensive tooling. The fibre-reinforced polymer composite (FRPC) material industry, in particular, has much to gain from AM's potential to open the design space for geometrically complex forms, including topologically optimized lightweight structures, while also reducing waste. The objectives of the proposed research activities are (1) to develop AM systems and feedstock materials that enable continuous fibre reinforced polymer composites that conform with industry standards and needs to be additively manufactured, (2) to expand the capabilities of AM to true 3-dimensional fibre placement particularly along curved surfaces and integrate these 3D toolpaths with existing finite element analysis software, and (3) to developed strategies for applying AM technologies to other classes of advanced high performance composite materials. The outcomes of this research will help reduce manufacturing costs for low series products with high geometrical complexities. These advanced materials and manufacturing capabilities will benefit suppliers to the aerospace, military, automotive, oil and gas, medical device, and sporting equipment sectors.