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Prototyping and Advanced Manufacturing

The MARS Center operates one of the most capable composite advanced manufacturing pilot-scale production facilities at any American university.

• CFAM Composite Fabrication (CF3D)

  

  We are experts in using continuous fiber additive manufacturing (CFAM) to produce advanced composite structures. Our system was made by Continuous Composites, Inc., called CF3D. 

  The revolutionary CF3D system combines high-performing composite materials with rapid-curing thermoset resins to create complex parts with full automation. 

  It has three main advantages:

  1. Low-cost raw materials (no prepreg tapes required)
  2. No need for vacuum bag processing (in-situ consolidation and cure)
  3. No need for autoclave curing
      

  These give us significant cost reduction and production capacity improvements, making this technology a next-generation method for composite structure manufacturing.

  It uses accurate fiber placement with unprecedented fiber steering capability (3-centimeter turning radius) and natural consolidation with near instantaneous photocuring matrix materials.

  This independently controls fiber (carbon, silica-based glass, or alumina/mullite ceramic) and matrix materials (carbon, silica, alumina, SiC, or UHTC precursor resins).

  The MARS Center specializes in processing of polymer matrix composites (PMC) produced by CFAM or other means, and processes the PMC preform into carbon/carbon (C/C) and ceramic matrix composites (CMC). We also specialize in photocurable matrix resins, preceramic polymers, and ceramic powders to produce the first continuous fiber additive manufactured CMC. Fiber and matrix materials can be swapped independently for design and manufacturing flexibility.

  The print dimensions are 9 feet by 4 feet by 4 feet, with a sixth-axis rotation bed available for agile large-scale composite layup. The MARS Center has fabricated the first oxide-based CMC materials (OCMC/Ox/Ox) using CFAM technology.

• Large Format Additive Manufacturing (LFAM): JuggerBot 3D

  

  The JuggerBot 3D is our large-format pellet extrusion 3D printer for ultra-fast printing of polymer-based composite tooling. 

  It can print acrylonitrile butadiene styrene (ABS), polycarbonate, or polyetherimide resins for 175-plus degrees Celsius curing temperatures. This enables agile and affordable manufacturing of composite tools in 1–2 days. The print dimensions are 3 feet by 4 feet by 4 feet. 

• Biesse CL Materia Large-Scale Composite Machining Center

  This is one of the largest composite machining centers at any American university, featuring a 5-axis computer numerical control (CNC) system with an optional sixth rotation axis. 

  The machining dimensions are 10 feet by 5 feet by 4 feet, for both dry and actively cooled machining operations.

• Resin Transfer Molding (RTM) and Vacuum-Assisted Resin Transfer Molding (VARTM)

  We have equipment for composite fabrication and infusion for rapid manufacturing of PMC, C/C, and CMC processing using the Polymer Impregnation Pyrolysis (PIP) method.

  Composite fabrication and infusion is also available via Resin Transfer Molding (RTM) and Vacuum-assisted Resin Transfer Molding (VARTM) for rapid manufacturing of PMC, C/C, and CMC processing using the Polymer Impregnation Pyrolysis (PIP) method.

Nondestructive Evaluation

The MARS Center operates one of the largest robotic X-ray computed tomography (CT) and laser ultrasonic testing (LUT) systems at an American university. 

Our specialized equipment can determine composite quality with complete internal inspection of composite parts without destructive sectioning. This is critical for aerospace components where you need confidence in the internal structure before high-value ground or flight testing, ensuring composite structures can meet design requirements.
 

• Radalytic Robotic X-ray CT System

  Our X-ray CT system can give you full volumetric internal inspection of composite and ceramic parts with robotic automation. 

  This system can be transported for specialized scanning of large structures or aircraft on site. The chamber size is 8 feet by 8 feet by 8 feet.

  

• Xarion Laser Ultrasonic Testing (UT)

  This provides noncontact ultrasonic inspection for delamination and porosity in composite structures. The laser system uses the same physics as standard water-coupled UT, but no longer requires water coupling. 

  Laser UT creates a pressure wave on the surface using a laser pulse and the response is then measured with a laser vibrometer to track how the pressure waves traverse the composite structure. Laser UT is more effective than air-coupled UT since there is no signal dampening from air gaps.

  

• 100-Ton High Temperature Press for Conventional Ceramic Powder Processing

  Our press is capable of high-temperature pressing up to 2,500 degrees Celsius for densification and consolidation of ceramics with 12-inch platens. 

  This traditional approach to ceramic processing complements the DCS-200 for materials that are not electrically conductive.

• Digital CMM and Large-Scale 3D Scanning

  We use a Keyence high-accuracy coordinate measuring system for dimensional inspection of complex geometry. Its blue light scanning technology can be used to scan 3D parts as large as 30 meters in length to create a digital model of any structure.

  

CNC Metal Machining

The MARS Center operates a complete computer numerical control (CNC) machine shop capable of machining both metal and composite materials to aerospace tolerances. 

This includes multi-axis CNC milling and turning, waterjet cutting for composites, and a surface grinder for precision finishing, all of which are supported by digital coordinate measuring machine (CMM) inspection.
 

• Haas TL2 CNC Lathe

  Our lathe can perform precision CNC turning for making metal and composite parts to aerospace tolerances.

  

• Haas TM2 CNC Mill

  The mill is capable of multi-axis CNC milling for complex metal and composite geometry.

  

• OMAX Waterjet

  This is a 10-foot-by-5-foot, abrasive waterjet cutting for composite structures and thick stock.

  

• Universal Laser Systems Laser Cutter

  Our machine provides precision laser cutting for thin composite and film materials.

  

• Grizzly G3155 Surface Grinder

  This performs precision surface finishing for tooling and machined components.

  

•  Manual Mill

  This mill can do manual milling for prototype work and fixturing.