The layer-by-layer nature  of AM makes it possible to strategically design cavities into a printed part and embed foreign components into in during the printing process.  This can enable “smart” multifunctional assemblies created directly on the build tray.  This project is investigating (1) how to automatically design cavities for embedding arbitrary geometries and (2) how to predict the impact of embedding on part failure through in-depth thermal modeling.

Material extrusion AM has the potential to revolutionize the construction of large-scale concrete structures in remote environments.  Specifically, using a large robotic arm to deposit concrete material enables unprecedented design freedom. However, the significant cure time required for concrete causes a dynamic build environment, where structures can deform as they are being printed.  This project is investigating how this build deformation can be predicted and how designs can be modified to account for it in advance.