Speedy composite manufacturing technique ‘could accelerate low-carbon flight’

A new technique that combines additive manufacturing with compressive moulding could accelerate the decarbonisation of aircraft and other vehicles, its developers have claimed.

The additive manufacturing compression moulding (AMCM) process was developed by a team at the US Department of Energy’s Oak Ridge National Laboratory (ORNL) in Tennessee.

AMCM first uses short-fibre-filled polymer and continuous fibre to print directly onto a mould with precise orientation, to make parts such as propeller blades or battery boxes. Compression moulding then turns the print into an accurate finished piece.

Researchers at ORNL used the technique to produce 100 parts in five hours, with each piece taking less than three minutes to print. The demonstration proved that the process could cut the time and cost of production, they claimed.

“By combining the fibre control of additive with the low porosity of compression moulding, we can enable the high-volume production of next generation composites,” said ORNL’s Vipin Kumar.

“The mobility and aerospace industries need these lightweight materials to improve the energy efficiency of their applications.”

The technique was recently licensed by Californian 3D printing and robotic automation firm Orbital Composites, which collaborated with the lab to install AMCM on a robotic system. Other collaborators included the Institute for Advanced Composites Manufacturing Innovation in Tennessee.

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