Publications

Mar, 2026

Conference Paper

Multiplexing core & sheath extrusion system development for additive manufacturing for inner-bead multi-material capability

Single-feed polymer extruders are widely used in large-format additive manufacturing (AM) systems; however, the increasing demand for multi-material functionality within a single part has driven significant innovation in this field. One approach involves robotic pick-and-place operations, while another explores mechanical switching of feed lines during extrusion. Although…

Mar, 2026

Conference Paper

Continuous Fiber 3D printing for Compression Over Molding

Mar, 2026

Conference Paper

EXPERIMENTAL INVESTIGATION OF SHORT FIBER REINFORCED THERMOPLASTIC COMPOSITE JOINING IN AN INTEGRATED ADDITIVE MANUFACTURING AND COMPRESSION MOLDING SYSTEM

Dec, 2025

ORNL Report

Design and production for maximum structural efficiency with respect to fiber orientation with increased understanding of hybrid fiber flow behavior

Nov, 2025

Journal

Subvoxel Control of Fiber Orientation via Multidirectional Shearing in 3D Printing

Anisotropy, the characteristic of materials exhibiting different properties based on their direction, is widespread in nature. Conventional manufacturing techniques often fall short in recreating such complex anisotropy. While 3D printing allows for precise fiber deposition in anisotropic composites, previous studies have only achieved bulk reorientation of fibers at the v…

Nov, 2025

Journal

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. The AM-CM process creates highly precise preforms by additively placing extru…

Nov, 2025

ORNL Report

A Novel Manufacturing Process of Lightweight Automotive Seats: Integration of Additive Manufacturing and Reinforced Polymer Composite

Sep, 2025

Journal

Numerical framework for integrated additive manufacturing-compression molding (AM-CM) of thermoplastic composites

Additive manufacturing-compression molding (AM-CM) has emerged as a transformative technology in advanced composite manufacturing. Additive manufacturing (AM) offers high design flexibility and the ability to produce complex geometries with precisely aligned fibers in the preferred orientation. Compression molding (CM) enhances composite materials by providing excellent di…

Sep, 2025

Journal

Influence of sizing concentration on strength, stiffness, and porosity in textile grade carbon fiber (TCF)-Epoxy composites: Revealing inverse trends

The effect of fiber sizing (i.e., surface treatment) concentration (0 %, 1.36 %, 1.52 %, 1.94 %, and 2.13 %) on the mechanical properties (tensile, flexural, interlaminar shear strength (ILSS), and low velocity impact) of textile grade carbon fiber (TCF)-epoxy composite is examined. An inverse relationship between the strength and stiffness of the composite is observed wit…

Sep, 2025

Journal

Macro-level mechanical interlocking: A rapid joining approach for additively manufactured compression molded composite panels

Composite joining typically involves multiple steps, such as drilling and surface treatment, as part of the manufacturing process, which leads to low throughput and long cycle times. In the present study, we demonstrated a macro-level mechanical interlocking (MI) based, rapid joining technique to assemble additively manufactured compression molded (AMCM) panels, enabling t…

Sep, 2025

Journal

Multiplexing Extrusion System Development for Increased Throughput, Flow Accuracy and Improved Microstructure

As additive manufacturing technologies advance and 3D-printers get larger, there is a constant need for larger extruders with higher throughput to quickly construct objects. Extruders can continually be made larger, but the weight of an extruder grows faster than its output, and larger/heavier extruders require a stiffer and more expensive gantries or robots to carry and c…

Aug, 2025

Journal

Benchmarking image processing techniques for porosity measurement in polymer additive manufacturing: Review and experimental analysis

An image processing workflow is proposed for porosity measurement in polymer additive manufacturing. Various techniques, including global and local thresholding, region growing, and K-means clustering, were applied to microscopic images of carbon fiber reinforced acrylonitrile butadiene styrene (CF-ABS) and benchmarked for their ability to accurately measure porosity. Glob…