Agile Ultrasonics Methodology for Continuous Ultrasonic Welding of Advanced Thermoplastic Composite Structures in CCA and AAM Vehicle Applications

Agile Ultrasonics leads innovation in designing and manufacturing thermoplastic composite welding systems essential for high-rate production of aero structures. Our company’s robotic end effectors are integral to processes such as welding, compacting, strengthening, and lightening carbon fiber reinforced thermoplastic composites (TPCs) intended for use by the US Air Force in CCA and AAM vehicles. Moreover, our technology is enabling more efficient and versatile dual-purpose manufacturing practices across defense and commercial aerospace, automotive, and consumer sectors. Data from prior work associated with NASA, AFRL and Tier-One aerospace component makers have demonstrated that Agile’s ultrasonic welding technology can be scaled to meet secondary and structural joining requirements of TPCs planned for use in Air Force CCA and AAM vehicles.  The work proposed specifically addresses the critical next step needed to advance our technology. Our proposal will focus on developing Closed Loop Control capabilities, which entail continuous ultrasonic welding where an array of sensors gathers in-weld data such as temperature, force, amplitude, and rate.  This information can be processed into machine responses/AI, prompting the weld system to make real-time parameter adjustments. This dynamic integration capability is essential for providing consistent, reliable, high-rate welding capabilities to meet the needs of CCA and AAM vehicles.  In support of this, weld trials of representative materials will be performed.  Test samples will undergo mechanical and non-destructive testing, and process iterations will need to occur to improve and validate the work.