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

I-Corps：纤维增强聚合物复合材料的自动化制造

• 批准号: 2345499
• 负责人: Mostafa Yourdkhani
• 金额: $ 5万
• 依托单位: Colorado State University
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2023
• 资助国家: 美国
• 起止时间: 2023-12-01 至 2024-11-30
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2345499&HistoricalAwards=false
• 关键词: Corps; Automated; manufacturing; fiber; reinforced

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.

该 I-Corps 项目更广泛的影响/商业潜力是纤维增强聚合物复合材料 (FRPC) 自动化制造的开发。所提出的技术可用于开发具有成本效益的轻质 FRPC 零件，用于航空航天、能源、汽车和生物医学等多种应用和行业。 FRPC 的传统制造依赖于昂贵的工具和模具、烤箱和高压釜中的长加热周期以及劳动密集型工艺，使得 FRPC 的生产速度缓慢且成本高昂。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以及在制造过程中材料的快速硬化。所提出的制造方法可以快速、经济高效且节能地生产定制复合材料零件。此外，所提出的无模具制造方法可以设计传统方法无法生产的复杂复合材料结构。新的设计能力可以支持更轻的地面和飞行器以及更大的风力涡轮机的开发，以实现更高效的能量转换。这个I-Corps项目基于先进制造平台的开发，用于快速和自动化制造高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沿着所需的 3D 路径放置浸渍有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。通过控制材料的放置来构建所需的结构，无需复合材料行业中常用的模具和工具。控制工艺参数可以制造具有低空隙率和高浓度碳纤维增强材料的 FRPC 部件。此外，原位固化和硬化复合材料的能力使得能够在空中进行自由形式、无支撑的制造，并实现三维增强。与传统方法相比，拟议的技术可以减少能源使用，从而实现更可持续的实践。该奖项反映了 NSF 的法定使命，并通过使用基金会的智力优点和更广泛的影响审查标准进行评估，被认为值得支持。