Advanced Additive Manufacturing Infrastructure: Towards Sustainable and Adaptive Manufacturing of More Complex and Continuous Fiber-Reinforced Composites

从传统制造到更具可持续性和适应性的制造实践的范式转变，导致人们越来越关注增材制造（AM）和纤维增强聚合物复合材料（FRPC），用于轻量化和多功能结构。这两个领域的结合面临着零件质量和设计完整性的挑战，尽管它们在各种行业和结构中的应用具有公认的潜力和规模。目前，多功能轻质结构高级研究实验室（ARL-MLS）研究团队使用传统的3D打印机来研究均质、短纤维注入和纳米颗粒注入的长丝系统。为了解决现有AM-FRPC解决方案的局限性并实现下一代功能部件，扩展ARL-MLS设施的当前能力至关重要，以启用和支持更复杂的frpc和连续frpc的复杂熔化、多材料和多物理性质。拟议的3D打印基础设施将为ARL-MLS团队提供关键能力，用连续纤维和其他复杂复合材料打印生产级的高级功能和多样化部件。提出的3D打印系统将为开发复杂和连续frpc表征的新方法提供必要的基础设施，研究结构和活性材料部件健康监测的自感知机制，以及原位过程监测技术的集成。拟议的设备将扩展ARL-MLS的现有设施，提供必要的能力和基础设施，以支持和实现当前和未来的研究活动，包括高级智能结构的表征、建模和测试，以及用于设计、质量控制和健康监测的智能工具的开发。这些研究活动的发展和进步将有助于提高3D/4D打印工艺的可靠性、通用性和性能，通过改善可持续性和制造实践，这将有利于并促进加拿大和许多行业的环境和经济增长。

The paradigm shift from conventional to more sustainable and adaptive manufacturing practices has led to an actively growing focus on additive manufacturing (AM) and fiber-reinforced polymer composites (FRPC) for lightweight and multifunctional structures. The conjunction of these two areas face challenges with part quality and design integrity, despite the recognized potential and scale of their applications to various industries and structures. Currently, the Advanced Research Laboratory for Multifunctional Lightweight Structures (ARL-MLS) research team uses conventional 3D printers to study homogeneous, short-fiber-infused, and nanoparticle-infused filament systems. To address the limitations of existing AM-FRPC solutions and actualize the next generation of functional parts, it is critical to expand the current capabilities of the ARL-MLS facilities to enable and support the intricate melting, multi-material, and multi-physics nature of more complex FRPCs and continuous FRPCs. The proposed 3D printing infrastructure will provide the ARL-MLS group the critical capabilities to print high-level functional and diverse parts at the production grade with continuous fibers and other complex composite materials. The proposed 3D printing system will provide the necessary infrastructure to develop novel methods for characterization of complex and continuous FRPCs, investigating the self-sensing mechanisms for health monitoring of structural and active material parts, and the integration of in-situ process monitoring technologies. The proposed equipment will expand the current facilities at the ARL-MLS with the essential capabilities and infrastructure to support and enable the current and future research activities involving the characterization, modelling, and testing of advanced smart structures, and the development of intelligent tools for design, quality control, and health monitoring. The development and progress of these research activities will be leveraged towards enhancing the reliability, versality, and performance of the 3D/4D printing process, which will benefit and promote growth across Canada and many industries environmentally and economically through improved sustainability and manufacturing practices.