Professor Paul Ziehl and his team at the University of South Carolina’s McNAIR Center for Aerospace Engineering and Research are using advanced technologies such as embedded sensors, edge computing, machine learning, and high-fidelity simulations to improve aerospace manufacturing. Their current focus is on detecting structural defects during manufacturing processes to reduce costs and speed production. The team is partnering with industry partners including Integer Technologies and Maher Advanced Composites to develop industrial solutions for aerospace manufacturing.
The team’s research is aimed at advancing the use of thermoplastic composites, which have the potential to replace traditional thermosets and reduce structural weight by 20%. Thermoplastics can be fusion or co-fusion welded, eliminating the need for rivets and bolts, and can be reshaped and reused. The team is working to improve advanced manufacturing processes to enable the use of thermoplastics in commercial aircraft production.
According to Ziehl, once thermoplastic composites are widely certified for aerospace applications, there are many advantages to their use, including lower-cost and more rapid manufacturing. The team’s research has attracted several contracts to study the physical condition of structures during and after manufacturing, and they are working to develop a highly skilled workforce and improve manufacturing processes.