Direct Digital Manufacturing of Integrated Naval Systems Using Ultrasonic Consolidation, Support Material Deposition and Direct Write Technologies

This project enabled the integration of ultrasonic consolidation, direct write dispensing, and material deposition technologies into a manufacturing workcell capable of fabricating advanced, integrated Naval-relevant structures. The workcell was shown to be capable of spatial composition control and complex internal geometries - including embedded electronics, thermal management, reinforcement fibers and other features - along with the resolution, scalability, repeatability, dimensional accuracy and surface finish of milling, all within an integrated Direct Digital Manufacturing (DDM) workcell. A one-year extension led to the development of a computational modeling infrastructure for ultrasonic consolidation that has revolutionized the prediction of the effects of process parameter variations on bonding, microstructure and mechanical properties of parts made using ultrasonic consolidation.