Publications

Aug, 2026

Conference Paper

Influence of Surface Treatment on the Interfacial and Mechanical Performance of Metal-Insert Overmolded Composites

Structural composites with metal inserts are gaining increasing interest enabling light weight design for energy efficiency, provide insulation, corrosion protection without compromising mechanical integrity. Such over molded metal-polymer composites show strong potential in many automotive and aerospace component parts, e.g. car bumper, chassis, door, brackets, fasteners,…

Jul, 2026

Conference Paper

Demonstration of high-rate manufacturing of π-joint using additive manufacturing

Bonded composite π-joints are critical to support wing geometries in aerospace/aircraft structures. Its lightweight and robust load-bearing capabilities/design guarantee high structural integrity and reliability. Current manufacturing techniques of π-joints are complex and laborious, and do not always offer high-quality joining. This study presents a high-rate manufacturin…

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

Large-scale additive manufacturing with reactive polymers

The focus on large-scale polymer Additive Manufacturing (AM) has previously been on thermoplastic materials. However, Magnum Venus Products (MVP) along with researchers at Oak Ridge National Laboratory’s (ORNL) Manufacturing Demonstration Facility (MDF) are introducing a unique AM system capable of depositing reactive polymers in a large format. The system’s footprint is 4…

Mar, 2026

Conference Paper

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

Mar, 2026

Conference Paper

Continuous Fiber 3D printing for Compression Over Molding

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

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…

Jul, 2025

Journal

Optimizing Processing Conditions for Additively Reinforced Thermoforming (ART) in Convergent Manufacturing

This study utilized additively reinforced thermoforming (ART) to enhance the thermomechanical properties of polyethylene terephthalate glycol (PETG) sheet. ART materials were produced by overprinting PETG/carbon fiber filament (PETG/CF) on neat PETG sheets at varying conditions. The mechanical properties of the PETG sheet, PETG/CF, and ART materials were assessed, showing…

Feb, 2025

Journal

Fast-rate joining of thermoplastic composites using integrated additive manufacturing and compression molding process

The integration of additive manufacturing (AM) technology with compression molding (CM), has emerged as a high-performance composite manufacturing technology in recent years. In the AM-CM process, quickly deposited AM preform on a mold undergoes a rapid compaction cycle to fabricate structurally robust composite parts due to highly controlled fiber alignment (from AM) and…

Dec, 2024

ORNL Report

Oak Ridge National Laboratory Thermoplastic Composite Joining of Pultruded Continuous Fiber Spars for Multi-Functional Battery Enclosure