Development of Multi-material Additive Manufacturing Technology

Name

Tomonaga Okabe
Professor
School of Engineering, Tohoku University Department of Aerospace Engineering Smart system materials and structure

Outline of Research

Due to its suitability for producing at scale, additive manufacturing (AM) is gaining interest in the aerospace industry. Using 3D printing to apply multi-material digital design practically is important for reducing the weight and cost of aircraft structural components and increasing the benefits of AM. There are high expectations for multi-material interior components which use thermoset CFRP and thermoplastic CFRP.
Multi-material design is a design concept that utilizes materials’ advantages and compensates for their disadvantages. To design such materials, it is essential to integrate the research and development of the actual manufacturing process (physical) with analysis tools (digital). On the physical side, advanced multi-material additive manufacturing (MAM) research is important. On the digital side, multiphysics and multiscale modeling tools to study the microstructure of materials or the integration of different properties in multi-materials can be combined with optimized design, including topology. This will facilitate multi-material digital design (MDD) in which multiple properties are considered. To maintain the strong position of Japan’s materials technology and continue its advancement, we promote research that combines the physical MAM and the digital MDD.

Research Purpose

To conduct research on and develop CFRP hybrid technology for next-generation structures in the aviation field, the following are fundamental issues for the realization of multi-material designs using thermoset and thermoplastic resins:
（１）Development of manufacturing conditions and equipment
（２）Development of adhesion and bonding technologies
（３）Multipurpose-optimized design, topological design, and biomimetic design
（４）Measures aimed at preventing damage, destruction, and environmental degradation
（５）Ensuring design flexibility
The project’s goal is to achieve practical application of digital design, bonding, and 3D printing of either metal and CFRP or CFRP and CFRTP.

Expected Effect

By focusing on aircraft interior components as a target for commercialization and practical application, and by delivering products that fully utilize the technologies developed, the company will have a distinct advantage over its overseas competitors. The company is expected to improve its ability to respond to demand and to increase its share of the commercial aircraft market.
As for the effectiveness of the policy and long-term vision, the realization of innovative multi-material additive manufacturing will significantly reduce the weight of aircraft bodies, which will contribute to a significant reduction in energy consumption and CO2 emissions. These innovations are expected to have an impact not only on the aviation industry, but also in reducing the weight and improving the safety of all modes of transportation, including emerging technologies such as flying cars.

Achievement

Projects
NEDO Pioneering Research Program “Development of Multi-material 3D Bonding and Optimum Molding Technology to Achieve High Reliability in the Field of Aeronautics,” FY2019
NEDO Project “Development of Technology for the High-Strength, High-Speed Joining and Assembly between Composites and Other Materials for Aircraft Components,” FY2020-2024
Domestic Symposiums
Sixth Symposium, Multi-Materials Research Center, Tokyo, February 1, 2024.
Fifth Symposium, Multi-Materials Research Center, Hybrid (Tohoku University / Online), January 30, 2023.
Forth Symposium, Multi-Materials Research Center, Online, January 24, 2022.
Third Symposium, Multi-Materials Research Center, Online, January 25, 2021.
Second Symposium, Multi-Materials Research Center, Tokyo, January 7, 2020.
Kick-off Symposium, Multi-Materials Research Center, Tokyo, January 10, 2019.

Joint Research Enterprise

Toray Industries, Inc., Jamco Corporation

Keywords

Additive manufacturing, multi-material, CFRP

SDGs

Contact Information

TEL：+81-22-795-6982
E-mail address: tomonaga.okabe.a8＊tohoku.ac.jp
Please use @ instead of ＊.
HP URL: http://www.plum.mech.tohoku.ac.jp/toppage.html