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THE PROPOSED WORK AIMS TO ADVANCE THE FUNDAMENTAL SCIENCE-BASED DESIGN RULES AND FABRICATION APPROACHES NECESSARY TO CREATE AEROSPACE-GRADE STRUCTURES FROM DIGITAL COMPOSITE MATERIALS. THE CONCEPT OF DIGITAL MATERIALS THAT USE OF DISCRETE BUILDING BLOCKS WHICH ARE A PHYSICAL INSTANTIATION OF DIGITAL VOXELS OFFERS A ROUTE FOR SCALABLE AND RAPID PRODUCTION OF STRUCTURES WITH DESIGNED STRUCTURAL CHARACTERISTICS. TO DATE HOWEVER DEMONSTRATIONS HAVE BEEN LIMITED TO ISOTROPIC MATERIALS THAT FAIL TO MEET THE EXACTING AEROSPACE STRUCTURAL LOAD DEMANDS OR HAVE BEEN TOPOLOGICALLY RESTRICTED TO 1-D AXIALLY LOADED STRUTS. THE PROPOSED WORK AIMS TO ADDRESS THESE PROMINENT SHORTCOMINGS VIA INVESTIGATION OF 1-D FIBER-REINFORCED COMPOSITE STRUTS THAT ARE COMPUTATIONALLY DESIGNED FOR INCREASED SPECIFIC STIFFNESS AND BUCKLING RESISTANCE AND 2-D ELEMENT POPULATIONS THAT HAVE TUNABLE AND DIRECTIONAL PROPERTIES THAT CAN RESIST TYPICAL CARBON FIBER-EPOXY MATRIX COMPOSITE LOADS. THE STRUCTURAL PERFORMANCE OF VARIED DESIGNS WILL BE COMPARED TO FINITE ELEMENT PREDICTIONS TO CLOSE THE LOOP ON THE DESIGN-FABRICATION-PERFORMANCE STRUCTURAL DESIGN CYCLE. THE METHODS PROPOSED TO ACHIEVE THESE GOALS INCLUDE: COMPUTATIONAL MODELING OF 1-D STRUT CROSS-SECTIONAL GEOMETRIES; HIGH-THROUGHPUT PULTRUSION OF A LIBRARY OF COMPUTATIONALLY DESIGNED 1-D CELLULAR ELEMENTS; NOVEL INTERNAL JOINING METHODS FOR SIMPLE AND ROBUST CONNECTIONS BETWEEN NEIGHBORING ELEMENTS; AND DESIGN AND AUTOMATED COMPOSITE FABRICATION AND PRINTING OF 2-D FIBER-REINFORCED PLATE ELEMENTS. EACH OF THESE METHODS IS BRIEFLY DESCRIBED AS FOLLOWS. A LIBRARY OF 1-D DISCRETE ELEMENTS WILL BE COMPUTATIONALLY DESIGNED FOR RELATIVE OPTIMALITY WITH RESPECT TO ELASTIC AND INELASTIC FAILURE CONDITIONS OVER A RANGE OF STRUCTURAL LOADING CONDITIONS. THE USE OF TENSEGRITY APPROACHES WITH BIFURCATED TENSILE AND COMPRESSIVE STRUT POPULATIONS WILL BE PURSUED FOR FURTHER MASS REDUCTIONS. THE FABRICATION OF 1-D AXIAL ELEMENTS WILL BENEFIT FROM THE LOW-COST HIGH-THROUGHPUT OF COMPOSITE PULTRUSION PROCESSING AND WILL EMBED CORE CAVITIES FOR REDUCED MASS. THE CREATION OF 2-D MODULAR ELEMENTS WILL HARNESS THE USE OF ADDITIVE MANUFACTURING TECHNOLOGY AS WELL AS MORE CONVENTIONAL COMPOSITE MANUFACTURING TECHNIQUES. THE INCLUSION OF FIBER REINFORCEMENTS AND THEIR DIRECTIONAL ORIENTATION OF 2-D PLATES OFFERS A RICH PARAMETER SPACE FROM WHICH TO OPTIMIZE THE STRUCTURE AND WILL BE CONSIDERED IN THE COMPUTATIONAL DESIGN OF A SET OF DISCRETE ELEMENTS THAT ARE SUPERIMPOSED ON SIMP-DERIVED TOPOLOGIES. THE PREDICTED MECHANICAL RESPONSE (MODULUS DEFLECTION FAILURE LOAD) OF BOTH 1-D AND 2-D ELEMENT STRUCTURES WILL BE TESTED UNDER TENSILE AND COMPRESSIVE LOADING AND CORRELATED WITH FINITE ELEMENT MODELS TO DETERMINE THE QUALITY OF COMPUTATIONAL PREDICTIONS. THE SIGNIFICANCE OF THE EXPECTED PROJECT RESULTS DIRECTLY IMPACT NASA S TECHNOLOGY ROADMAP PARTICULARLY TA12 (MATERIALS STRUCTURES MECHANICAL SYSTEMS&MANUFACTURING). THE PROPOSED COMPUTATIONAL DESIGN TOOLS AND FABRICATION TOOLS FOR 1-D AND 2-D DISCRETE COMPOSITE ELEMENTS WILL ENABLE MODULAR STRUCTURAL DESIGNS THAT ARE OPTIMIZED FOR STIFFNESS MASS AND ROBUSTNESS. MOREOVER THE VERSATILITY AND MATERIAL EFFICIENCY OFFERED BY THE DESIGN-PRINT-DEPLOY APPROACH WILL OFFER ON-DEMAND PRINTABLE MANUFACTURE OF THE MODULAR COMPONENTS THAT IS UNIQUELY SUITED TO SPACE-BASED ENVIRONMENTS. THE MATERIAL BLOCKS WILL UTILIZE FIBER-REINFORCED AND HYBRID COMPOSITE MATERIALS TO SIMULTANEOUSLY ATTAIN THE PROPERTY LEVELS EXPECTED WITHIN THE AEROSPACE COMMUNITY AND THE UNPRECEDENTED ABILITY TO REPURPOSE DEFUNCT SPACE STRUCTURES. THIS AMORTIZATION OF THE STRUCTURAL EXPENSE OVER MULTIPLE GENERATIONS OF STRUCTURES WILL AIM TO ACHIEVE A MORE SUSTAINABLE LAUNCH COST STRUCTURE. THE MODULAR DESIGN PROVIDES A PATHWAY FOR CHARACTERIZATION OF DISCRETE ELEMENTS TO SERVE AS INPUTS INTO STRUCTURAL MODELS IN AN EFFORT TO AVOID COSTLY AND LENGTHY SUB-COMPONENT CERTIFICATION.

$579,501FY2014National Aeronautics and Space AdministrationNASA

University Of Massachusetts Lowell, Lowell MA

Investigators

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