Publications

Mar, 2026

Conference Paper

Detecting thermal crack growth on a large additive manufactured structure using acoustic emission

Large format additive manufacturing (LFAM) proved to have a great potential to become an adjacent technology to traditional manufacturing methods. One of the sectors LFAM is targeting is rapid tool/mold development for composites. This includes large mold structures used for high-temperature molding techniques (in-oven or autoclave). Although, these large printed structure…

Mar, 2026

Conference Paper

Characterizing the Thermal-Induced Distortion of Large-Scale Polymer Composite Printed Structures

The Big Area Additive Manufacturing (BAAM) system has been used to print large-scale parts, such as automotive structures and molds for tooling, with fiber-reinforced polymer composites. Incorporating reinforcing fibers in printed parts is commonly used to increase stiffness and strength, but it also introduces significant anisotropy in the thermomechanical performance, wh…

Nov, 2025

ORNL Report

CRADA Final Report: CRADA Number NFE-24-10036 with ThermaMatrix, Inc.

Nov, 2025

ORNL Report

Evaluation and Development of Phase Array Ultrasonic Testing (PAUT) System for Additively Manufactured Parts

This research focuses on the application of advanced ultrasonic testing techniques developed by The Phased Array Company (TPAC) for inspecting defects in additive manufacturing (AM) parts. Traditionally, X-ray computed tomography is the standard for inspecting AM components. Although, the long inspection and analysis time, along with relatively high cost make implementatio…

Jun, 2024

ORNL Report

STRUCTURAL HEALTH MONITORING FOR LARGE-SCALE ADDITIVE MANUFACTURING USING ACOUSTIC EMISSION TECHNIQUE

Nov, 2023

Conference Paper

3D PRINTED LAYER OF POLYANILINE-BASED CONDUCTIVE POLYMER FOR LIGHTNING STRIKE PROTECTION OF CFRPS

Manufacturing of Carbon Fiber Reinforced Plastics (CFRPs) using additive manufacturing (AM), or 3D printing, has gained popularity in recent years. It is believed that the AM industry has the potential to manufacture CFRP parts in a faster, easier and more economical way. Lightning strike damage to CFRP parts is not rare; therefore, additional lightning strike protection (…

Nov, 2023

Journal

Performance of hybridized bamboo-carbon fiber reinforced polypropylene composites processed using wet laid technique

The end-of-life vehicles (ELV) regulations motivate hybrid materials usage in automotive industries to optimize properties at reduced cost and increase eco-friendly designs. This research explores hybrid compositions of natural bamboo fiber and synthetic carbon fiber. The goal of hybridization was to synergistically benefit from each constituent– i.e., sustainability, ener…

Nov, 2023

Journal

An Innovative Digital Image Correlation Technique for In-Situ Process Monitoring of Composite Structures in Large Scale Additive Manufacturing

As additive manufacturing (AM) continues to develop and become a standardized manufacturing method, there will be a continued need to provide in-situ monitoring during the manufacturing of polymer composite printed components. Thermal residual stress is a primary cause of failures such as interlayer disbonds or delamination, micro cracking, and dimensional instability, whi…

Nov, 2023

Journal

MXene Reinforced Thermosetting Composite for Lightning Strike Protection of Carbon Fiber Reinforced Polymer

Ti3C2 – a member of the MXenes (2D transition metal carbides and nitrides) family, is investigated as an effective filler to improve the electrical, mechanical, and thermal properties of divinylbenzene (DVB) thermosetting resin. Consequently, its performance as a lightning strike protection (LSP) coating for carbon fiber reinforced polymer (CFRP) is evaluated. Polyaniline…

Nov, 2023

Conference Paper

Large-scale continuous carbon/glass fiber additive-compression molded composites

Additive Manufacturing (AM) or 3-D printing has advanced from small-scale desktop printers to large-scale printers. Most of the present large-scale printers utilize feedstock materials in the form of pellets to create composite structures. To create structurally robust composite parts, reinforcements in the form of short fibers (carbon or glass) are often used to impart me…

Nov, 2023

Conference Paper

Experimental and Numerical Investigations on Dynamic Mechanical Properties of TPMS Structures

Triply Periodic Minimal Surface (TPMS) lattice structures have been of increasing interest due to their light weighting, enhanced mechanical properties, and energy absorption characteristics for automotive and biomedical applications. With the advent of additive manufacturing and geometric modeling software, TPMS lattices with complex geometries can be realized. In this wo…

Oct, 2022

Conference Paper

Applying Acoustic Emission to Large Format Additive Manufacturing

Large format additive manufacturing (AM) is being adapted as a method of producing large structures in a short lead time and cost-effective way. With the growing advancement in AM techniques and application, machine monitoring and part qualification is highly needed. There has been leading research focused on the manufacturing development and feedstock material but minimum…