Abstract: An additive manufacturing system for additive manufacturing material with long fibers includes an extruder comprising a nozzle that includes a static-mixing portion, a compression portion, and a long fiber alignment portion. The static-mixing portion includes a static-mixing channel with static-mixing rods distributed inside and extending radially inward from a channel wall. The long fiber alignment portion has an alignment channel with a diameter DAC that is less than a diameter DSMC of the static-mixing channel. The compression portion includes with a reducing diameter from an input end to an output end of the compression channel. A nozzle and method for additive manufacturing are also disclosed.

Abstract: A hybrid additive manufacturing and thermoforming method is provided. The method includes additively manufacturing one or more reinforcing structures directly onto a polymer sheet before shaping the polymer sheet onto a mold and/or while the polymer sheet is shaped onto a mold. By leveraging the design control of additive manufacturing, reinforcing structures can be deposited onto the polymer sheet as needed based on the intended application. These reinforcing structures can comprise standard infill patterns or complex custom core designs. The present invention provides an innovative way in which to mass produce custom thermoformed components with an optimal mechanical response.

Abstract: An additive manufacturing system for additive manufacturing material with long fibers includes an extruder comprising a nozzle that includes a static-mixing portion, a compression portion, and a long fiber alignment portion. The static-mixing portion includes a static-mixing channel with static-mixing rods distributed inside and extending radially inward from a channel wall. The long fiber alignment portion has an alignment channel with a diameter DAC that is less than a diameter DSMC of the static-mixing channel. The compression portion includes with a reducing diameter from an input end to an output end of the compression channel. A nozzle and method for additive manufacturing are also disclosed.

Abstract: The current embodiments include all-polymeric protective material for mitigating lightning strike damage. The protective material includes a hybrid matrix comprising PANI and MXene dispersed within a thermosetting epoxy resin. This hybrid matrix can be painted, printed, or applied as a conductive polymeric layer to a FRCP structure, for example an aircraft fuselage, wing, empennage, control surface (aileron, flap, slats, rudder, elevator) or a wind turbine blade. The protective material not only withstands lightning strikes, but also functions as shielding against electromagnetic interference and is corrosion-resistant and lightweight.

Abstract: The current embodiments include all-polymeric protective material for mitigating lightning strike damage. The protective material includes a hybrid matrix comprising PANI and MXene dispersed within a thermosetting epoxy resin. This hybrid matrix can be painted, printed, or applied as a conductive polymeric layer to a FRCP structure, for example an aircraft fuselage, wing, empennage, control surface (aileron, flap, slats, rudder, elevator) or a wind turbine blade. The protective material not only withstands lightning strikes, but also functions as shielding against electromagnetic interference and is corrosion-resistant and lightweight.

Abstract: A polymeric adhesive film including a conductive filler of polyaniline (PANI) and MXene is provided. The adhesive film can be painted, printed, or applied to different substrate structures, including aircraft and wind turbine blades. The adhesive film has potential as a fatigue sensor, a strain sensor, a gas sensor, a humidity sensor, and a temperature sensor, by non-limiting example. In one embodiment, a force sensing material includes a conductive filler of PANI and MXene within an organic or polymer matrix. The force sensing material is used to measure local mechanical strain by detecting the change in electrical conductivity induced by the mechanical strain. The force sensing material can also be used in other applications where local strain changes, including the detection of local humidity and local temperature.