Publications

Showing 46 results for Author: Katie E. Copenhaver

View All publications

Sep, 2026

Journal

Autonomous Layer Time Optimization in Large-format Additive Manufacturing through Machine Vision and Feedback Control

Proper thermal management in large-format additive manufacturing (LFAM) to maintain geometric control and mechanical integrity requires, in part, maintaining the substrate, or the previously deposited layer temperature, within a defined process window. Temperatures that are too low result in weak interlayer bonds; conversely, elevated temperatures cause geometric instabili…
Aug, 2026

Journal

Healable Coatings as a Mechanism to Repair Leading Edge Erosion in Wind Energy

Wind turbine blades are highly engineered structures designed to face temperature extremes and high winds. However, erosion of the blade's leading edge and subsequent repair remains a significant and costly challenge for the wind energy industry. Repair of these leading edges can lead to large amounts of downtime for the turbine and significant operational inefficiencies.…
Aug, 2026

Conference Paper

Additively Reinforced Thermoformable PETG Composite Sheets for Improved Structural Efficiency

Thermoforming of short-fiber reinforced thermoplastic sheets offers a viable pathway for producing lightweight composite components; however, inherent anisotropy in fiber reinforced sheets can limit structural performance under multidirectional loading. In this work, short carbon fiber, glass fiber, and hybrid fiber–reinforced PETG sheets were evaluated as candidate feedst…
Aug, 2026

Journal

Harnessing biomass-derived reinforcements for sustainable flame-resistant composite

Bio-based composites containing natural fiber reinforcements have been integral to developing innovative, low-cost, and low-energy technologies for transportation applications in marine, automotive, and other industries. The low density of natural fibers gives these materials a high specific stiffness and strength, which can lead to significant weight savings in composites…
Jul, 2026

ORNL Report

BIODEGRADABLE BIOCOMPOSITE DEVELOPMENT FOR LARGE SCALE ADDITIVE MANUFACTURING

Oak Ridge National Laboratory (ORNL) worked with Mitsubishi Chemical America, Inc. to develop a highly biodegradable ~100% biobased feedstock for large format additive manufacturing (AM). Together, they developed a AM feedstock based on the biobased polyester, polybutylene succinate (PBS), that is typically used in agriculture and packaging projects. The motivation for thi…
Jul, 2026

Journal

Solvent-Mediated Control of Nanocellulose Dispersion: An Integrated Computational and Experimental Investigation

Fibrillated cellulose derived from forestry feedstocks represents a renewable and high-strength materials platform for circular bioeconomies. However, its practical implementation is hindered by the irreversible aggregation of nanocellulose architectures, including cellulose nanofibers (CNFs). Solvent-based dispersion offers a simple and practical route to prevent CNF aggr…
Jul, 2026

Journal

Hybrid Bio-Based Composites: Enabling Cellulose Nanofiber (CNF) Incorporation into Composites via Macroscale Natural Fiber Carriers

Cellulose nanofibers (CNFs) have significant potential in composites as additives to improve mechanical properties, melt rheology, and more. However, agglomeration of CNFs is a key challenge in composite melt processing as obtaining nano-level dispersion of CNFs often requires cost- and energy-intensive processes (e.g., solvent exchange or freeze drying) due to the strong…
Jun, 2026

Journal

High-loading 3D-printed open-cell zeolite catalysts with enhanced structural integrity

3D-printed catalysts with open-celled structures can significantly reduce mass and heat transfer resistance compared with traditional pellet counterparts. However, current 3D printing techniques typically achieve only about 70 wt% zeolite loading. While higher loading is desirable to improve catalyst performance, it also increases slurry viscosity, leading to printing chal…
Jun, 2026

Journal

Citric Acid Functionalized Natural Fibers to Enhance Thermal Stability and Moisture Resistance in Polylactic Acid Composites

Cellulosic fibers can impart many unique benefits into composite applications, such as reduced weight or structural reinforcement, however, these materials also increase hygro-scopicity and decrease thermal stability – restricting broader application. The present work adapted an experimental process for functionalizing the cellulose surface using cit-ric acid (CA). Functio…
Jun, 2026

Conference Paper

Additively Reinforced Thermoformable PETG Composite Sheets for Improved Structural Efficiency

Thermoforming of short-fiber reinforced thermoplastic sheets offers a viable pathway for producing lightweight composite components; however, inherent anisotropy in fiber-reinforced sheets can limit structural performance under multidirectional loading. In this work, short carbon fiber, glass fiber, and hybrid fiber–reinforced PETG sheets were evaluated as candidate feedst…
Mar, 2026

Journal

Effect of fiber sizing and glass fiber laminate hybridization on vibration damping and mechanical properties of banana fiber reinforced polypropylene composites

Modern automotive applications demand lightweight, multifunctional materials to reach mileage goals and natural fiber reinforced composites (NFRCs) are one of the classes of materials proposed as a solution. NFRCs exhibit good vibration damping properties and have low density, but are often limited by processing challenges, poor-fiber matrix compatibility and variable perf…
Mar, 2026

Conference Paper

Effect of Internal Structure on Warpage in a Large-Scale Additive Manufacturing Process With Bio-Derived Composites

Extrusion-based large-format additive manufacturing (LFAM) often results in unintended deformation and failures due to thermal residual stress between layers. This LFAM involves a hot molten polymer deposited on a previously deposited and cooled layer, generating a temperature mismatch between the layers. The temperature discrepancy causes a thermal contraction mismatch, g…

Explore

Quantum

AI

Reactors

Fuel Cycle

Materials

Resources for Biology

Neutrons

Publications

Autonomous Layer Time Optimization in Large-format Additive Manufacturing through Machine Vision and Feedback Control

Healable Coatings as a Mechanism to Repair Leading Edge Erosion in Wind Energy

Additively Reinforced Thermoformable PETG Composite Sheets for Improved Structural Efficiency

Harnessing biomass-derived reinforcements for sustainable flame-resistant composite

BIODEGRADABLE BIOCOMPOSITE DEVELOPMENT FOR LARGE SCALE ADDITIVE MANUFACTURING

Solvent-Mediated Control of Nanocellulose Dispersion: An Integrated Computational and Experimental Investigation

Hybrid Bio-Based Composites: Enabling Cellulose Nanofiber (CNF) Incorporation into Composites via Macroscale Natural Fiber Carriers

High-loading 3D-printed open-cell zeolite catalysts with enhanced structural integrity

Citric Acid Functionalized Natural Fibers to Enhance Thermal Stability and Moisture Resistance in Polylactic Acid Composites

Additively Reinforced Thermoformable PETG Composite Sheets for Improved Structural Efficiency

Effect of fiber sizing and glass fiber laminate hybridization on vibration damping and mechanical properties of banana fiber reinforced polypropylene composites

Effect of Internal Structure on Warpage in a Large-Scale Additive Manufacturing Process With Bio-Derived Composites