Grant: Alliance Grants

Additive manufacturing (AM) of composites is a very promising technology that enables manufacturing of components featuring complex geometries and multifunctionalities for various applications including aerospace. The development of composite AM requires a better understanding of the interactions between the manufacturing parameters, the transformed material and the cohesion between the layers, in order to identify ways of improving the productivity and quality of the printed parts to meet the requirements for commercialization and be economically viable for production. The proposed 5-year project focuses on innovative and breakthrough research on critical topics at the state-of-the-art of advanced AM processes and simulation tools for the production of multifunctional composite parts for aerospace applications. This project will be carried out in close collaboration with Safran Group and two Quebec companies (Dyze Design, ORS Inc.). The four specific objectives (O) of the project were defined by the academic team and the industrial partners and they are: (O1) Optimize parts' mechanical performance and process productivity in AM through a fundamental understanding of the materials-process relationship; (O2) Develop simulation tools for accurate prediction of printed parts' mechanical properties focusing on the interface; (O3) Develop a high-throughput multi-nozzle 6-axis robot-assisted AM process for the direct deposition of acoustic structures for aerospace applications; and (O4) Develop a customized and visual tool for assessing and optimizing the circularity potential of AM parts. This project will train ~40 HQP, yield significant scientific and technological contributions in the fields of advanced AM and microstructure analysis while performing technology transfer to our three industrial partners and contribute to the sustainability of the developed processes. Another direct benefit for Canada is that this project will create at least 9 jobs in high technology SMEs, which will help them increase their profit and open new markets. Finally, this project will support the Canadian vision of zero waste for thermoplastics for a concept of recycling and reprocessing, having direct environmental and social impacts.