Title: Ultrasonic Welding of Thermoplastic Composites for In-Space Manufacturing and 3D Printed Structure Reinforcement Applications

Authors: Jim Stratton

DOI: 10.33599/nasampe/c.25.167

Abstract: Thermoplastic composites demonstrate enhanced performance over thermoset composites in specific applications, largely attributable to their inherent weldability, which provides a considerable advantage in manufacturing and structural integrity. The ability to weld these materials simplifies the manufacturing process by enabling precise assembly of complex geometries, thereby reducing production costs and increasing throughput. Moreover, the weldability of thermoplastics improves maintainability, facilitating the efficient reconfiguration [6], repair or replacement of damaged components. This capability not only prolongs the operational lifespan of the materials but also reduces system downtime, ultimately enhancing overall performance and reliability. In this paper, we explore the ultrasonic welding of thermoplastic composites, which employs high-frequency mechanical vibrations to induce heat at material interfaces via intermolecular friction and viscoelastic heating mechanisms. Two case studies focused on the ultrasonic welding of carbon fiber reinforced thermoplastic (CFRTP) and glass fiber reinforced thermoplastic (GFRTP) composites are presented, examining both plunge and continuous (scan) welding techniques using Agile Ultrasonics technology [4]. The applications discussed include: (1) ultrasonic welding trials conducted on prototype CFRTP composite L-brackets for a lunar tower, integral to NASA’s Thermoplastic Development for Exploration Applications (TDEA) project aimed at in-space manufacturing of CFRTP composite structures; and (2) ultrasonic welding trials of pre-impregnated and preconsolidated multi-axial GFRTP laminates onto 3D-printed polymer assemblies produced by Avient Corporation for exoskeletal reinforcement [3].

References: 1. Miller, S.G., Pinakidis, J., Bryant, R., Lang, C., Bergan, A., Segal, K. "Innovations in Continuous Ultrasonic Welding of Thermoplastic Composites and Evaluation for Space Applications." Thermoplastic Composites Conference, San Diego, CA, March 26-28, 2024. 2. Miller, S.G. "Thermoplastics Development for Exploration Applications (TDEA) Presentation at Agile Ultrasonics." NASA Glenn Research Center, February 6, 2025. 3. Spiegel, J. "Introduction of Continuous Fiber Thermoplastic Tapes and Laminates into 3D Printed Structures Utilizing Ultrasonic Scan Welding." Polystrand, Avient Corporation. SPE ACCE Conference, Novi, MI Sept 2023. 4. Stratton, J. " CW tech days Jim Stratton presentation." CompositesWorld Tech Days, April 18, 2025. 5. ASTM D790-17, 2017, "Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials," ASTM International, West Conshohocken, PA. DOI: 10.1520/D0790-17. 6. Pinakidis, J., Miller, S.G. "Joining Disassembly and Reconfiguration of Thermoplastic Composites for Space Applications." CAMX Conference Proceedings, San Diego, CA, September 9-12, 2024. CAMX – The Composites and Advanced Materials Expo. 7. ASTM D5868-01, 2014, “Standard Test Method for Lap Shear Adhesion for Fiber Reinforced Plastic (FRP) Bonding,” ASTM International, West Conshohocken, PA. DOI: 10.1520/D5868-01R14.

Conference: CAMX 2025

Publication Date: 2025/09/08

SKU: 167

Pages: 13

Price: $26.00