DESC0023772

With this DOE SBIR Phase I proposal, Free Form Fibers is aiming to demonstrate a bio-inspired methodology to insert self-contained, self-powered sensors within multifunctional structural fiber reinforcements. This approach is especially suited for sensors [and actuators] for harsh environments, such as nuclear reactors. The envisioned technology of fiber-embedded systems, as well as its business model, are inspired by the phenomenal success of Micro-Electro-Mechanical-Systems (MEMS), which are now present in every smartphone, vehicle, and most consumer electronics. Contrary to MEMS, however, the proposed fiber-embedded systems are not add-on, but rather an integral part of composite materials. They are envisioned as seamlessly integrated, non-invasive, wireless, and an alternative to add-on fiber-optics sensors. The necessary manufacturing technology is protected under US and International patents. It is a form of Containerless, Material-Agnostic, Additive Manufacturing, specialized for filamentary structures and is referred to 1½-D Printing. The proposed approach is quite generic. If demonstrated for one type of sensor – say heat flux – the same approach can be used for other sensing devices (e.g., neutron flux). The approach also has a great potential for integrated structural health monitoring in both nuclear and non-nuclear applications. By analogy to MEMS, the expectation is that mass manufacturing can bring down the per device cost so low that a large number can be integrated into a composite structure, forming the technological equivalent of a “nervous system.” Sensor interrogation is expected via microwave radio frequency, and lead to interpretation using Digital Twins, or Machine Learning and Artificial Intelligence. Ultimately, such a strategy could displace stationary non-destructive evaluation with on-board structural health monitoring.