3D Printing of Multifunctional Composite Sandwich Structures with Reinforced Interfaces and Integrated Electronics

The U.S. Navy has identified a significant capability gap in sandwich composite structures used in both aerospace and marine applications. Current sandwich composites suffer from core and face-sheet interface debonding, especially when subjected to multiaxial loading. Traditional manufacturing methods operate within a limited design space that cannot provide rational load paths for complex geometries. Additionally, existing sandwich structures lack multifunctionality, resulting in added weight and complexity when integrating sensing, communication, or other capabilities. The Navy seeks advanced sandwich composite structures with improved bond strength and multifunctionality via performance-driven design customization. While 3D printing technology can produce complex core topologies, increasing bonding strength between face-sheets and cores remains a significant challenge. Current technologies utilize adhesive bonding which creates weak interfaces susceptible to failure and adds manufacturing complexity, weight, and cost.ÝTo meet this urgent US Navy need, AnalySwift LLC, in collaboration with the University of Illinois at Urbana-Champaign (UIUC), proposes to develop a new concept of 3D-printed multifunctional composite sandwich with reinforced interfaces and integrated electronics, which leverages optimization-driven design, single-process composite additive manufacturing, and thin-film electronics integration to create next-generation sandwich structures. The optimization design is based on AnalySwiftís commercial products including SwiftComp and DATC (Design Tool for Advanced Tailorable Composites) and will also employ our extensive work on multiscale modeling, optimization, and advanced manufacturing technologies. The proposed work will also leverage our university partnerís expertise and Navy-funded projects in advanced composite manufacturing and thin-film electronics integration. For instance, the optimized 3D printed structures will utilize continuous carbon fiber reinforced thermoplastic (CCF-TPs or CCFRTPs) skins and a cellular core. CCF-TPs are composite materials where continuous carbon fibers are embedded within a thermoplastic matrix. These materials offer a combination of high strength, stiffness, and lightweight properties, making them suitable for various applications, especially in industries like aerospace and defense.Ý