Data Driven Scalable Composites Manufacturing Processes

ABSTRACT:
In the continuously evolving landscape of manufacturing, data-driven approaches are serving as catalysts for a technological revolution, fundamentally reshaping conventional methods of composite manufacturing into adaptable, efficient, and scalable systems. The scalability of manufacturing processes exhibits substantial variation contingent upon numerous factors, including the specific process characteristics, employed technology and equipment, and the availability of resources. Scalability is not a universally linear concept; rather, it hinges upon multifaceted considerations. In numerous instances, the expansion of composite manufacturing processes necessitates thorough process optimization to uphold product quality and efficiency. The efficacy of this optimization hinges upon the extent to which the process can be seamlessly adapted to produce larger components or the scaling up of production volumes. In this talk we will shed the light on several examples of scaling up different manufacturing processes, such as thermoplastic and thermoset Additive Manufacturing (AM) processes, compression molding for automotive parts, as well as the facilitation of pioneering integrated polymer manufacturing processes. One of the foremost advantages offered by data-driven manufacturing lies in its capacity to foster continuous improvement. This talk will encompass different data-driven scalability aspects ranging from material development, advanced materials characterization, system integration, data analysis, and economic considerations. Through the accumulation and systematic analysis of data over time, manufacturers can identify trends and pinpoint opportunities for refinement, both within the manufacturing process itself and in the end-product.

BIO:
Ahmed Arabi Hassen, PhD, is the Group Leader for the Composites Innovation (CI) Group in the Manufacturing Science Division (MSD) at Oak Ridge National Laboratory (ORNL). He is leading ORNL's development efforts in high-rate manufacturing of advanced composites structures. Ahmed is leading ORNL’s molds and dies manufacturing portfolio for the composite manufacturing industry. One of his leading efforts is to develop a vision and strategies for smart manufacturing of polymers and advanced composites aiming to advance the U.S. competitiveness in the global market of manufacturing. Dr. Hassen contributed to the creation of a new market for Additive Manufacturing (AM) technologies by developing a new class of composite feedstock materials for large-scale AM systems. He has expertise in a wide variety of composite manufacturing, characterization, and qualification methods and he is currently leading/managing several technical research efforts with a large funding portfolio in this field. Dr. Hassen is mentoring, supporting, and managing a group of undergraduate and graduate students (PhD and Masters), postdoctoral fellows, and junior/senior staffs. Dr. Hassen was serving on the Board of Directors (BOD) of the American Society for Non-destructive Testing (ASNT) and was the Chairman of the ASNT Research Symposium (2020-2022). He has published 90+ articles in high impact journals and proceedings, holds several patents, has received three R&D 100 Awards, named the 2021 Society of Manufacturing Engineers (SME), Jud Hall Composites Manufacturing Award recipient in addition to multiple honors and technical awards.