Duration: 18 months
MorphoComp4D is currently led by international researchers in 4D printing of structural composites (IRDL UMR CNRS University of South Brittany in France and Concordia University in Canada) supported by Thales Alenia Space and Ariane Group for technical specifications and Coriolis Composites for the manufacturing purpose. Although additive manufacturing allows design freedom through a careful material deposition, the technology is limited by unwanted material distortion induced by thermal residual stresses. The objective of the project is to evidence the potential of using these residual stresses generated during Automatic Fibre Placement (AFP) and Fused Filament Fabrication (FFF) to propose a disruptive out of mold paradigm to produce high performance composite structures. Using 4D printing and biomimicry paradigm, residual stresses will be turned into an advantage to design and build complex self formed composites structures at flat state that will reach their final shape by a subsequent thermal stimulation. Three proofs of concept with incremental complexity (a composite spring, a conical shape for Vespa and a double curved shell for half-fairing) will be proposed at lab scale. Their final shape will be obtained through i) specifications and requirements given with supporting companies (TAS and Ariane Group), ii) a proper material selection and characterization of high performance thermoplastic composites that are compatibble with AFP and FFF process, iii) a better knowledge on the residual stresses and especially heat shrinkage mechanism, iv) the constitution of a library of the various typology of self shaping given by the mechanical simulation and v) a tailored material deposition given an algorithmic inverse problem resolution inspired from Origami design. Finally, a demonstrator of self-formed composite will be proposed using novel hybridized AFP/FFF at industrial scale thanks to Coriolis Composite commitment.
