Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “function alignment”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 487 records · Page 27

Space station docking mechanism dynamic testing

A prototype docking mechanism for the Space Station was designed and fabricated for NASA. This docking mechanism is actively controlled and uses a set of electromechanical actuators for alignment and load attenuation. Dynamic tests are planned using the Marshall Space Flight Center's 6-DOF Motion Simulator. The proposed tests call for basic functionality verification as well as complete hardware-in-the-loop docking dynamics simulations.

Howsman, Thomas G.↗

MHD Instability and Turbulence in the Tachocline

In this quarter we have begun simulations on the Cray T3E at PSC and we are debugging our code on the TSC. The PSC simulations are examining stratified shear turbulence with a flow-aligned magnetic field and passive tracer particles. We have conducted analysis of neutral simulations to establish a firm basis of comparison. Second-order structure functions have been computed, fit, and compared to theoretical expressions relating the dissipation fields and the structure-function-fit parameters. Agreement with high-Reynolds number observations is excellent, giving us confidence that the lower-Re simulations are relevant to higher-Re flows. We have also evaluated the neutral layer anisotropy.

Werne, Joseph↗

Alignment-Insensitive Lower-Cost Telescope Architecture

This architecture features an active wavefront sensing and control scheme along with methods for measuring the relative positions of the primary to aft optics, such as the secondary mirror, and should enable larger and cheaper telescope architectures needed for future applications. A wavefront source/sensor is placed at the center of curvature of the primary mirror. The system provides continuous light onto a primary mirror that is retro-reflected onto itself. This allows the wavefront controller to constantly update the positions of the primary mirror segments (or deformable mirror actuators). Another function of this innovation involves using a concave mirror on the back of the secondary mirror (or other aft optic) that has the same center-of-curvature location (in defocus) as the primary mirror. The two return beams can be aligned next to each other on a detector, or radially on top of each other. This provides a means with which to measure the relative position of the primary to the secondary (or other aft optics), thus allowing for the removal of misalignment of the center-of-curvature source/sensor (meaning it doesn't need precision placement) and also provides a means with which to monitor the relative alignment over time. This innovation does not require extremely good thermal stability on the primary mirror and can thus be used in any thermal environment and with cheaper materials. In addition to this, the architecture lets one phase (or align) the primary mirror independent of whether a star or scene is in the field. The segmented, spherical primary allows for cost-effective three-meter class (e.g. Midex and Discovery) missions as well as enabling 30-meter telescope solutions that can be manufactured in a reasonable amount of time. The continuous wavefront sensing and control architecture enables missions for low-Earth-orbit.

Feinberg, Lee↗

Ultraviolet Spectropolarimetry with Polstar: Interstellar Medium Science

Continuum polarization over the UV-to-microwave range is due to dichroic extinction (or emission) by asymmetric, aligned dust grains. Scattering can also be an important source of polarization, especially at short wavelengths. Because of both grain alignment and scattering physics, the wavelength dependence of the polarization, generally, traces the size of the aligned grains. Similarly because of the differing wavelength dependencies of dichroic extinction and scattering polarization, the two can generally be reliably separated. Ultraviolet (UV) polarimetry therefore provides a unique probe of the smallest dust grains (diameter<0.09 μm ), their mineralogy and interaction with the environment. However, the current observational status of interstellar UV polarization is very poor with less than 30 lines of sight probed. With the modern, quantitative and well-tested, theory of interstellar grain alignment now available, we have the opportunity to advance the understanding of the interstellar medium (ISM) by executing a systematic study of the UV polarization in the ISM of the Milky Way and near-by galaxies. The Polstar mission will provide the sensitivity and observing time needed to carry out such a program (probing hundreds of stars in the Milky Way and dozens of stars in the LMC/SMC), addressing questions of dust composition as a function of size and location, radiation- and magnetic-field characteristics as well as unveiling the carrier of the 2175 Å extinction feature. In addition, using high-resolution UV line spectroscopy Polstar will search for and probe the alignment of, and polarization from, aligned atoms and ions - so called “Ground State Alignment”, a potentially powerful new probe of magnetic fields in the diffuse ISM.

B-G Andersson↗

The Utilization Profiles of the CCSDS Unified Space Link Protocol (USLP)

The purpose of this paper is to identify the utilization profiles for interfacing the Data Protocol Sublayer using the Unified Space Link Protocols (USLP) (reference 1) with the space link coding procedures as specified in the CCSDS Coding & Synchronization Blue Books (references 2 through 5), used in both telecommand and telemetry applications. This paper describes how the USLP Protocol utilizes the coding and synchronization sublayer to support: a. Direct to Earth (DTE) telemetry links for engineering and science data b. Direct to Earth (DTE) telemetry links for very high rate science data c. Direct from Earth (DFE) command, sequencing and flight software loads d. Space to Space Links (Proximity) utilized by orbiters for data exchange to/from surface bound assets. The CCSDS has divided the functions of the Data Link Layer into two sublayers: the Data Link Protocol Sublayer (DLP-SL) and the Coding and Synchronization Sublayer (CS-SL). The Data Link Protocol Sublayer (DLP-SL) interfaces to the users, accepting the data that is to be transported, on the sending side of the link, and delivering that data on the receiving end. The Transfer Frame is the data unit that is transferred across the Data Link Protocol Sublayer and the Coding and Synchronization Sublayer boundary. The Coding and Synchronization Sublayer (CS-SL) provides the encoding, randomization, and frame synchronization functions that prepares the USLP Transfer Frame for transport across the space link. The CS-SL is divided into 2 processes: 1) The Frame Interface Processes (FIP) performs the interface functions required to prepare the data for delivery to the Coding/Decoding Process (CDP). This process includes prepending a Frame Start Marker to the provided frame, when management has designated that the frame is not to be aligned to the codeblock or when there is no block code used. 2) The Coding/Decoding Process (CDP) performs the forward error correction processes that are used to optimize the performance of the link and minimize the error rate. The CDP creates the symbol stream that is delivered to the Physical Layer. The transfer of the USLP transfer frames across different types of space links is the focus of this paper. The Protocol Data Unit (PDU) that is passed in both directions between the Data Link Protocol Sublayer (DLP-SL) and Coding and Synchronization Sublayer (CS-SL) is the transfer frame. The USLP frame structure provides flexibility that can be constrained by the functions utilized within the CS-SL that prepare the transfer frame for transit. For example, the USLP transfer frame contains a length field that enables the frame to be of variable length but CS-SL under certain conditions may constrain the frame to be fixed in length. This paper describes 5 operational modes available for use by the Data Link Layer to provide data exchange across the USLP space link. These modes are different because different operational requirements apply to vastly different types of space links and thus the communications implementation requirements differ. The environmental issues include the power or energy available, the distance between the end points of the link, the complexity of the equipment available at those end points, the atmospheric conditions and radiometric frequency selection. The CS-SL utilizes different forward error correcting codes supported by specific operational modes to configure the data for transit. This paper describes all of the operational modes in a series of data models which decompose the functionality between the Data Link Protocol Sublayer and the Coding and Synchronization sublayer. The operational modes described are: 1. Uncoded Mode: has been used for short links that contain significant available power to provide an acceptable frame error rate. The frames in this mode can be variable in length and typically use an error detection algorithm (i.e., CRC) to determine if there are errors in the received frame. 2. Convolutional Only Mode: is currently the prime forward error correction coding used for the proximity links. The frames in this mode can be variable in length and typically use an error detection algorithm (i.e., CRC) to determine if there are errors in the received frame. 3. Variable Length Frame Aligned to Variable Length Codeblock (TC): is used for Direct from Earth links were power levels are high and the simple, least complex code i.e., the BCH code is used. This mode has been in use since the early 1970s. The BCH code is a short code and the decoder is easy to implement. 4. Fixed Length Frame Aligned to Fixed Length Codeblock (AOS/TM): was introduced when the concatenated Convolutional and Reed-Solomon Code was formulated to provide significant reduction in link data error rate and the ability to determine if there was an error in the decoded codeblock. The frame is aligned to the codeblock so that there is a one to one relationship of frame errors to codeblock errors without additional error detection coding being added. This mode requires the protocol frames to be the exact size of the message portion of the codeblock. 5. Frames Unaligned to Fixed Length Codeblocks (Currently used for very high rates and space to space links): This mode is currently used for missions that have a very high data rate that can be controlled adaptively as the environment changes and as the next generation operating mode for the proximity link. This mode from a coded data stream point of view is exactly like that described in 4. above, except that the frame need not be aligned to the codeblock. There is no requirement on frame length when using this mode. Thus when using USLP it can be used to support links that require short or long frames. There is also no mandatory requirement that frames cannot be separated by idle data reducing the tight data rate connection requirements between the data link protocol sublayer and the coding & synchronization sublayer. In conclusion, how these operational modes can be put to use in mission operational scenarios is described for Direct from Earth links (DFE), Direct to Earth links (DTE), and Proximity links.

Greenberg, E.↗

Chemistry of Titanium Deposition Precursors for Area-Selective Deposition of Functionalized Silicon [Posters]

Area-selective atomic layer deposition (AS-ALD) is an appealing bottom-up fabrication technique that can produce atomic-scale device features, overcoming challenges in current industrial techniques such as edge alignment errors. TiCI 4 is a common thermal ALD precursor for Ti0 2 thin films, which are appealing candidates for DRAM capacitors due to their excellent dielectric constants. Hydrogen and chlorine termination passivate the Si surface, allowing for selective deposition of TiCI 4 onto HO-terminated areas. However, selectivity loss occurs after several ALD cycles. Ti oxide nucleates onto surface defects on Cl- and H-Si resists. Previously, the use of H-Si as an ALD resist has been studied extensively, but less work has focused on chemical forces driving nucleation, especially for Cl-Si. Here, formation of defect nuclei was investigated with selectivity loss during Ti0 2 ALD with TiCI 4 and water on the (100) and (111) crystal surfaces of hydrogenated, chlorinated, and oxidized Si.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

A novel conditional formulation of the Vlasov–Ampère equations: a conservative, positivity, asymptotic and Gauss law preserving scheme

We propose a novel reformulation of the Vlasov–Ampère equations for plasmas that reveals discrete symmetries that enables simultaneous conservation of mass, momentum and energy; preservation of Gauss’s law; positivity of the distribution function; and consistency with quasi-neutral asymptotics. The approach employs variable and coordinate transformations to yield a coupled system comprising a modified Vlasov equation and associated moment–field equations. The modified Vlasov equation advances a conditional distribution function that excludes mass, momentum and energy densities, which are instead evolved through moment equations enforcing the relevant symmetries, conservation laws and involution constraints. This reformulation aligns naturally with a recent slow-manifold reduction technique, which separates fast electron time scales and simplifies the treatment of the quasi-neutral limit within the reduced moment–field subsystem. Using this framework, we develop a numerical method for the reduced 1D1V subsystem that, for the first time in the literature, satisfies all key physical constraints while maintaining a quasi-neutral asymptotic behaviour. The advantages of the method are demonstrated on canonical electrostatic test problems, including the multiscale ion acoustic shock wave.

1D1V↗

Magneto-optical Kerr effect in an A-type antiferromagnet

Magneto-optic Kerr effect (MOKE) is a powerful probe of broken time-reversal symmetry (T$${{\mathcal{T}}}$$), typically used to study ferromagnets. While MOKE has been observed in some antiferromagnets (AFMs) with vanishing magnetization, it is often associated with structures whose symmetry is lower than basic collinear, bipartite order. In contrast, theory predicts a mechanism for MOKE intrinsic to all AFMs of A-type, i.e. layered AFMs in which ferromagnetic layers are antiferromagnetically aligned. Here we report the experimental confirmation of this mechanism in a bulk AFM. We achieve this by measuring the imaginary component of MOKE as a function of photon energy in MnBi2Te4, an A-type AFM where T$${{\mathcal{T}}}$$ is preserved in combination with a translation, and comparing the experimental results with model calculations. Our model suggests that observable MOKE should be expected in all collinear A-type AFMs with out-of-plane spin order, thus enabling optical detection of AFM domains and expanding the scope of MOKE to few-layer AFMs.

Sunko, Veronika↗

Profiling expression strategies for a type III polyketide synthase in a lysate-based, cell-free system

Abstract Some of the most metabolically diverse species of bacteria (e.g., Actinobacteria) have higher GC content in their DNA, differ substantially in codon usage, and have distinct protein folding environments compared to tractable expression hosts like Escherichia coli . Consequentially, expressing biosynthetic gene clusters (BGCs) from these bacteria in E. coli often results in a myriad of unpredictable issues with regard to protein expression and folding, delaying the biochemical characterization of new natural products. Current strategies to achieve soluble, active expression of these enzymes in tractable hosts can be a lengthy trial-and-error process. Cell-free expression (CFE) has emerged as a valuable expression platform as a testbed for rapid prototyping expression parameters. Here, we use a type III polyketide synthase from Streptomyces griseus , RppA, which catalyzes the formation of the red pigment flaviolin, as a reporter to investigate BGC refactoring techniques. We applied a library of constructs with different combinations of promoters and rppA coding sequences to investigate the synergies between promoter and codon usage. Subsequently, we assess the utility of cell-free systems for prototyping these refactoring tactics prior to their implementation in cells. Overall, codon harmonization improves natural product synthesis more than traditional codon optimization across cell-free and cellular environments. More importantly, the choice of coding sequences and promoters impact protein expression synergistically, which should be considered for future efforts to use CFE for high-yield protein expression. The promoter strategy when applied to RppA was not completely correlated with that observed with GFP, indicating that different promoter strategies should be applied for different proteins. In vivo experiments suggest that there is correlation, but not complete alignment between expressing in cell free and in vivo. Refactoring promoters and/or coding sequences via CFE can be a valuable strategy to rapidly screen for catalytically functional production of enzymes from BCGs, which advances CFE as a tool for natural product research.

59 BASIC BIOLOGICAL SCIENCES↗

Unraveling the magnetic ground state in the alkali-metal lanthanide oxide Na 2 ⁢Pr⁡O 3

Here, a comprehensive set of muon spin spectroscopy and neutron scattering measurements supported by ab initio and model Hamiltonian simulations have been used to investigate the magnetic ground state of Na 2 ⁢PrO 3 . μSR reveals a Néel antiferromagnetic order below T N ~ 4.9K, with a small static magnetic moment m static ≤ 0.22 μ B /Pr collinearly aligned along the c axis. Inelastic neutron measurements reveal the full spectrum of crystal field excitations and confirm that the Pr 4+ ground-state wave function deviates significantly from the Γ 7 limit that is relevant to the Kitaev model. Single- and two-magnon excitations are observed in the ordered state below T N =4.6K and are well described by nonlinear spin wave theory from the Néel state using a magnetic Hamiltonian with Heisenberg exchange J=1 meV and symmetric anisotropic exchange Γ/J=0.1, corresponding to an XY model. Intense two magnon excitations are accounted for by g-factor anisotropy g z /g ± = 1.29. A fluctuating moment δm 2 = 0.57 ⁢(22) ⁢μ$^2_B$/Pr extracted from the energy and momentum integrated inelastic neutron signal is reduced from expectations for a local J = 1/2 moment with average g factor g avg ≈ 1.1. Together, the results demonstrate that the small moment in Na 2 ⁢PrO 3 arises from crystal field and covalency effects and the material does not exhibit significant quantum fluctuations.

36 MATERIALS SCIENCE↗

Hyperspectral imaging of exciton confinement within a moiré unit cell with a subnanometer electron probe

Electronic and optical excitations in two-dimensional systems are distinctly sensitive to the presence of a moiré superlattice. Here we used cryogenic transmission electron microscopy and spectroscopy to simultaneously image the structural reconstruction and associated localization of the lowest-energy intralayer exciton in a rotationally aligned WS 2 -WSe 2 moiré superlattice. In conjunction with optical spectroscopy and ab initio calculations, we determined that the exciton center-of-mass wave function is confined to a radius of approximately 2 nanometers around the highest-energy stacking site in the moiré unit cell. Our results provide direct evidence that atomic reconstructions lead to the strongly confining moiré potentials and that engineering strain at the nanoscale will enable new types of excitonic lattices.

36 MATERIALS SCIENCE↗

Prototype Imaging Spectrograph for Coronagraphic Exoplanet Studies (PISCES) for WFIRST-AFTA

Prototype Imaging Spectrograph for Coronagraphic Exoplanet Studies (PISCES) is a lenslet array based integral field spectrometer (IFS) designed for high contrast imaging of extrasolar planets. PISCES will be used to advance the technology readiness of the high contrast IFS baselined on the Wide-Field InfraRed Survey Telescope/Astrophysics Focused Telescope Assets (WFIRST-AFTA) coronagraph instrument. PISCES will be integrated into the high contrast imaging testbed (HCIT) at the Jet Propulsion Laboratory (JPL) and will work with both the Hybrid Lyot Coronagraph (HLC) and the Shaped Pupil Coronagraph (SPC) configurations. We discuss why the lenslet array based IFS was selected for PISCES. We present the PISCES optical design, including the similarities and differences of lenslet based IFSs to normal spectrometers, the trade-off between a refractive design and reflective design, as well as the specific function of our pinhole mask on the back surface of the lenslet array to reduce the diffraction from the edge of the lenslets. The optical analysis, alignment plan, and mechanical design of the instrument will be discussed.

Wide-Field InfraRed Survey Telescope Astrophysics ↗

Validation of Fitness for Duty Standards Using Pre- and Post-Flight Capsule Egress and Suited Functional Performance Tasks in Simulated Reduced Gravity (Pilot Egress Fitness)

As NASA prepares for exploration missions, it will be critical to understand and build upon known crew capabilities. Specifically, we need to know the functional capacities of crew at different stages of a mission and characterize these profiles so that the appropriate vehicle requirements and mission concepts of operations (ConOps) can be developed. One of the most complex phases of any missions is when there is a transition between gravity environments. For instance, both physiological adaptation to microgravity and subsequent re-entry into a gravity environment result in reduced functional capacity, even with rigorous adherence to inflight countermeasures. Quantification of the astronauts’ post-landing functional performance is necessary to design ConOps for exploration missions. Specifically, these two high-risk tasks may have to be performed soon after gravity transitions: •Unassisted capsule egress task after return to Earth •Planetary extravehicular activity (EVA) soon after landing on Mars or the Moon This study has been broken down into two phases. A pilot phase to assess the overall feasibility and demonstrate the capability to do these tasks shortly after landing and the full Egress Fitness study, which will be part of the CIPHER complement. This study uses a functional task approach to characterize performance of these high-risk tasks in long-duration ISS crewmembers before flight and shortly after return to Earth. Prior to any testing, each astronaut subject completes a suit fit check to ensure adequate sizing and mobility to be able to complete the EVA tasks. Pilot Egress Fitness pre-flight and post-flight testing includes an Earth based emergency egress out of a functional capsule mockup, and a short Mars gravity EVA simulation including suit donning, hatch egress, ladder descent, task board cable operations, baggage transfer over sand/rocky regolith, alignment with a rear entry port, and suit egress. Pre-flight testing can occur almost anytime pre-flight, but post-flight scheduling is much more critical with the capsule egress test occurring 1-4 hours after landing and the planetary EVA approximately 18-36 hours after landing. Data collected for both tasks includes task completion time, photo, and video. The EVA portion also includes collection of metabolic and heart rate. Pilot Egress Fitness study has completed baseline pre-flight testing on 3 astronaut subjects. Post-flight testing of the first two subjects will be completed in November 2021 and the final subject around March 2022. Results and lessons learned from this pilot study will inform the full Egress Fitness study, which will incorporate additional pre-flight sessions, longer EVA tasks, and post-flight testing on R+1, 4, and 7 to characterize the timeframe of recovery

J R Norcross↗

Validation of Fitness for Duty Standards Using Pre- and Post-Flight Capsule Egress and Suited Functional Performance Tasks in Simulated Reduced Gravity

The transition between gravity environments will involve one of the most complex, high-risk phases of any mission. For example, the reduced functional capacity caused by physiological deconditioning adaptations in microgravity coupled with the stressors of re-entry into partial gravity environments will increase risks to crew, even with rigorous adherence to inflight countermeasures. Quantification of the astronauts’ post-landing functional performance is necessary to design ConOps for exploration missions. Specifically, these two high-risk scenarios may be required to be performed soon after gravity transitions: • Nominal and/or emergency unassisted capsule egress task after return to Earth • Planetary extravehicular activity (EVA) soon after landing on Mars or the Moon This study is broken down into two phases. Phase 1: A feasibility study that will assess the overall feasibility and demonstrate the capability to do these tasks shortly after landing. Phase 2: the full Egress Fitness study, which is part of the CIPHER complement. This study uses a task-based approach to characterize functional performance of these high-risk scenarios in long-duration ISS crewmembers before flight and shortly after return to Earth. Prior to any testing, each astronaut subject completes a suit fit check to ensure adequate sizing and a mobility assessment to confirm completion of the EVA tasks. Pilot Egress Fitness pre-flight and post-flight testing includes an Earth-based emergency egress out of a functional capsule mockup and a short Mars gravity EVA simulation including suit donning, hatch egress, ladder descent, task board cable operations, baggage transfer over sand/rocky regolith, alignment with a rear entry port, and suit egress. Pre-flight testing will occur at any time point prior to flight. Post-flight assessment is much more critical with the capsule egress test that will occur 1–4 hours after landing and the planetary EVA approximately 18–36 hours after landing. The CIPHER study will incorporate additional pre-flight sessions, longer EVA tasks that include traverse and geology sampling, and post-flight sessions on R+1, 4, and 8 to characterize the timeframe of recovery. Data collected for both tasks include task completion time, photo, and video. The EVA portion also includes collection of metabolic and heart rate. Pilot Egress Fitness study has completed both baseline and post-flight testing on four astronaut subjects, with all four able to complete post-flight EVA testing and three able to complete postflight capsule egress testing. Preliminary results observe individual physiological variations, which were to be expected but also suggest the need to carefully track the timeline from undock to landing to testing. Furthermore, some task performance instructions and equipment may need to be adjusted to ensure results are primarily physiological. These and other lessons learned will be addressed with minor protocol changes in the full CIPHER Egress Fitness study.

J R Norcross↗

HYBRID MANUFACTURING TECHNIQUE USING LARGE-SCALE ADDITIVE MANUFACTURING AND COMPRESSION MOLDING FOR HIGH PERFORMANCE COMPOSITES

Additive Manufacturing (AM) or 3-D printing has moved from small-scale prototypes to large-scale functional structures. With the introduction of large-scale 3D printers into the market a new industry has been born. For the first time, we are presenting the idea of preparing large-scale 3-D printed β-stage preforms to be used in traditional compression molding (CM) manufacturing technique to prepare final functional structures. Short carbon fiber (CF) reinforced material acrylonitrile butadiene Styrene i.e. ABS with 20% CF is used in present work. It is shown that highly aligned 3D printed short carbon fiber composite maintains its orientation after compression molding. A sandwich panel is prepared to show the capability to prepare complicated parts by integrating AM and CM. Interphase of the prepared dissimilar material is also studied using SEM. Samples prepared using AM-CM integration showed 11% and 79 % improvement in tensile strength and tensile modulus respectively compared to the traditional extrusion compression molding (ECM) process.

Kumar, Vipin↗

Code for multi-shape Gaussian process (GP) fitting with uncertainty quantification (UQ)

This is code associated with the publication “Nonparametric Multi-shape Modeling with Uncertainty Quantification,” authored by Hengrui Luo (Lawrence Berkeley National Laboratory) and Justin Strait (Los Alamos National Laboratory). The code is used to fit multiple-output Gaussian process (GP) models of planar closed curves to collections of ordered point sets, allowing for flexible nonlinear prediction of the underlying curve under dense or sparse point set samplings and with or without noise, as well as tractable uncertainty quantification. To do this, we employ use of a periodic kernel to account for the nonlinear input space of closed curves, and combine with coregionalization models to account for dependence both (i) between curve coordinates, and (ii) between pairs of curves. Functions in the code are capable of fitting these models, as well as performing additional tasks with the fitted curves such as (a) shape registration and alignment, (b) shape averaging, and (c) fitting for curve sub-populations / clusters.

Strait, Justin↗

Genesis of a novel high-rate composite manufacturing process using large-scale additive manufacturing – compression molding (AM-CM) system: Possibilities and limitations

Oak Ridge National Laboratory (ORNL) has developed a highly automated manufacturing process for thermoplastic composites that combines the benefits of Additive Manufacturing and Compression Molding (AM-CM) to produce high-performance functional composite structures at automotive production rates. Here, the AM-CM process creates highly precise preforms by additively placing extruded fiber-filled polymers (with controlled fiber orientations and multi-material configurations) in the desired mold location before undergoing a secondary compression molding process immediately before the preform cools down. Preforms can be in the form of short, long-chopped, or continuous fiber-filled thermoplastic polymers (e.g., CF/GF-filled ABS, PC, LM-PAEK, etc.). The AM-CM process combines the benefits of controlled fiber alignment, that is only achievable in AM-printed parts with the classical CM process, which eliminates porosity and good surface finish. A preform created using AM-CM can integrate various materials to enable additional architectural functionalities, including over-molding, selective stiffening, and the incorporation of electrically or thermally conductive channels. All these advantages come with a fast part production cycle time. The AM-CM process can manufacture multi-material, multi-functional parts in under 3 min, starting from raw material (pellets) to the final product. The novel AM-CM process offers superior microstructural control and enhanced multi-functionality previously unattainable with any other traditional high-rate thermoplastic composite manufacturing method. This work covers the manufacturing concept, system development, materials and applications of AM-CM process in detail.

Kumar, Vipin [Oak Ridge National Laboratory (ORNL)↗