Title:

Convergent High-Rate Manufacturing of Composites: Advancing the Science of Scalability

Speaker:

Dr. Ahmed Hassen

Affiliation:

Oak Ridge National Laboratory

When:

Monday, February 17, 2025 at 11:00:00 AM   Add to Calendar

Where:

Boggs Building, Room 3-47

Host:

Dr. Aaron Stebner
aaron.stebner@gatech.edu

Abstract

The evolving landscape of composite manufacturing demands strategies that integrate fundamental science with scalable, convergent high-rate production methodologies. Convergent manufacturing, combining additive manufacturing, injection and compression molding, machining, and thermoforming, enables high-rate production without compromising performance or efficiency. Scalability extends beyond increasing production volume or part size; it requires a deep understanding of fundamental material properties and behavior, process interactions, system adaptability and manufacturing dynamics to ensure consistency and reliability. This talk explores key scientific principles governing scalability in composite manufacturing, focusing on thermoplastic and thermoset composite development, characterization, and advanced manufacturing. In particular, it will examin discontinuous fiber-reinforced composites, their use in large-format additive manufacturing and convergent systems, and how materials can be tailored for novel integrated systems as additive manufacturing-compression molding to optimize fiber orientation and overall part performance. Additionally, advancements in convergent systems such as Additively Reinforced Thermoforming (ART) will be discussed, highlighting how tailored reinforcements improve load distribution and enhance thermoformed structures. The talk covers convergent manufacturing from a materials perspective, focusing on multifunctional material development and how material properties can be tailored for specific applications and manufacturing methods. Special attention will be given to processing-structure-property relationships, manufacturing-induced defects, and strategies to address scale-up challenges while ensuring structural integrity and performance. By bridging the gap between fundamental research and industrial manufacturing, this talk will provide a technical roadmap for advancing convergent composite manufacturing, demonstrating how scientific advancements in materials and processing drive higher efficiency, improved quality, and broader industry adoption.

Biography

Dr. Ahmed Arabi Hassen is the Group Leader of the Composites Innovation (CI) Group in the Manufacturing Science Division (MSD) at Oak Ridge National Laboratory (ORNL). He is a leading expert in high-rate and convergent manufacturing of advanced polymers and composites, integrating additive manufacturing, machining, thermoforming, injection and compression molding, and other hybrid processes to improve efficiency, scalability, and performance. His work in large-format additive manufacturing (LFAM) has driven new markets by developing high-performance composite feedstocks for AM systems. His expertise spans composite processing, characterization, and qualification, and he manages multiple high-impact research initiatives with a strong funding portfolio. Dr. Hassen leads ORNL’s molds and dies manufacturing science portfolio and develops smart manufacturing strategies to enhance U.S. competitiveness in composites manufacturing. Dr. Hassen has 90+ publications, over 12 patents, and three R&D 100 Awards. He was the 2021 SME Jud Hall Composites Manufacturing Award recipient and has received multiple honors for his contributions to advanced manufacturing sciences. In addition to his research leadership, Dr. Hassen is committed to mentoring and developing the next generation of scientists and engineers, overseeing a team of undergraduate and graduate students, postdoctoral fellows, and junior/senior R&D staff members. His leadership extends beyond ORNL, he is an Adjunct Professor at the University of Tennessee, has served on the Board of Directors of the American Society for Non-Destructive Testing (ASNT), and was Chair of the ASNT Research Symposium (2020-2022). He also actively contributes to technical committees for Society for the Advancement of Material and Process Engineering (SAMPE).

Notes

Refreshments will be served.