Multifunctional composites have gained significant interest as they enable the integration of sensing and communication capabilities into structural, lightweight composites. Researchers have explored additive manufacturing processes for creating these structures through selective patterning of electrically conductive materials onto composites. Thus far, multifunctional composite performance has been limited by the conductivity of functional materials used, and the methods of integration have resulted in compromises to both structural and functional performance. Integration methods have also imposed limitations on part geometry due to an inability to adequately deposit conductive material over concave surfaces. Proposed methods of integrating functional devices within composites have been shown to negatively affect their mechanical performance. This work presents a novel method for integrating printed electronics onto the interior surfaces of closed, complex continuous fiber composite structures via the transfer of selectively printed conductive inks from additively manufactured sacrificial tooling to the composite surface. The process is demonstrated by creating multifunctional composites via embossing printed electronics onto structural composites without negatively affecting the mechanical performance of the structure. Additionally, this process expands the ability to pattern devices onto complex surfaces and demonstrates that the transferred functionality is well integrated (adhered) with the composite surface. The process is further validated through the successful completion of two separate case studies. The first is the integration of a functioning strain gauge onto an S-glass/epoxy composite, while a second process demonstration shows a composite surface featuring a band stop filter at the X-band, otherwise known as a frequency selective surface (FSS), to show the process' suitability for high performance, aerospace grade multifunctional composites. / Master of Science / Significant interest has been given in the past few decades to strong, lightweight materials for structural purposes. Among these materials, specific interest has been paid to fiber-reinforced composites, which are made of strong fibers and advanced resins. Recently, researchers have tried to use electrically conductive inks and 3D printing techniques to put antennas and other devices onto composites. These composites could possess additional functions beyond their structural purpose and are therefore called multifunctional composites. So far, the performance of multifunctional composites has been limited by the methods used to add additional functions. These methods often result in a weaker composite material and poor performance of the added devices. In this work, a new method for integrating devices onto complex-shaped composite structures is demonstrated. This is done by printing a mold for a composite, then putting a conductive ink onto the mold and transferring the ink to the composite surface. This process is demonstrated without weakening the composite. Additionally, this process allows researchers to put devices onto complex surfaces and demonstrates that the devices are secured to the composite surface. The process is used to make two separate devices and combine them with a composites surface. The first demonstration is the integration of a functioning strain gauge (used to measure a change in material dimension) onto a structural composite, while a second process demonstration shows a composite surface featuring an electromagnetic filter, otherwise known as a frequency selective surface (FSS), to show the process' suitability for high performance, aerospace grade multifunctional composites.
| Identifer | oai:union.ndltd.org:VTETD/oai:vtechworks.lib.vt.edu:10919/110462 |
| Date | 07 June 2022 |
| Creators | Viar, Jacob Zachary |
| Contributors | Materials Science and Engineering, Williams, Christopher Bryant, Davis, Bradley A., Case, Scott W. |
| Publisher | Virginia Tech |
| Source Sets | Virginia Tech Theses and Dissertation |
| Language | English |
| Detected Language | English |
| Type | Thesis |
| Format | ETD, application/pdf |
| Rights | In Copyright, http://rightsstatements.org/vocab/InC/1.0/ |
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