1. Manufacturing Capabilities
Polymer and Composite Manufacturing
- Compression molding using multiple heated presses (7.5-ton and 12-ton capacity) for thermoplastic, thermoset, and powder-binder composite systems
- Hot pressing and mechanically assisted forming for polymer and composite materials up to approximately 400–500 °C
- Thermoplastic annealing and fusion joining
- Stamp forming and pressure-assisted composite consolidation
- Support tooling for polymer composite layup, forming, and consolidation
Injection Molding
- Four injection molding machines, including:
- Two manual lever-driven systems
- One pneumatic injection molding system
- One hydraulically actuated cyclic injection molding machine
- Capable of processing:
- Thermoplastics
- Highly filled polymer–powder feedstocks (up to approximately 90% powder by volume)
- Maximum processing temperatures of approximately 315°C
- Maximum injection pressures approaching 16 MPa (2300 PSI)
- Suitable for rapid prototyping, small-batch production, and process-structure-property investigations
Additive Manufacturing
- Fused Filament Fabrication (FFF) systems adapted for:
- Polymer materials
- Particle-filled composite filaments
- Powder-based metal and ceramic filaments
- Single- and dual-independent extrusion platforms for multi-material printing
- Typical printing resolutions of approximately 300 µm depending on material system
- Validated printing workflows for copper, bronze, and stainless-steel powder filaments
- Laser Powder Bed Fusion (LPBF):
- Access to metal LPBF systems for fabrication of dense structural metallic components
- Suitable for research on design for metal additive manufacturing, support strategy development, and mechanical performance evaluation
- Resin-Based Additive Manufacturing:
- LCD-based vat photopolymerization systems for high-resolution polymer printing
- Capable of fine-feature fabrication for tooling, molds, fixtures, and structural prototype components
- Suitable for dimensional-accuracy studies and design-validation builds
Debinding and Sintering
- Two CO₂-assisted thermal debinding and sintering furnaces suitable for polymer binder removal and part densification
- One vacuum tube furnace with inert gas (argon) capability and a 40 mm working chamber
- Purely thermal debinding workflows compatible with PLA-based binder systems
- Mobile furnace systems enabling both laboratory-based and field-deployable processing
- Supporting infrastructure including:
- Alumina debinding and sintering crucibles
- Sintering paper and ballast media
- Controlled-atmosphere processing accessories
Machining and Fabrication Infrastructure
- Full traditional machine shop including:
- Manual and CNC milling and turning centers
- Drilling, tapping, sawing, grinding, and finishing equipment
- Wire electrical discharge machining (EDM) for precision tooling and component fabrication
- Custom mold, fixture, and test coupon tooling development
Materials Handling and Processing Support
- Powder drying and dehydration chambers
- Particle size control via mechanical sieving (metal powder)
- Large-scale extrusion equipment for polymer and composite compounding
- Dedicated laboratory space for material preparation and manufacturing
2. Mechanical Characterization and Testing Capabilities
Mechanical Testing Systems
- Universal testing machines with load capacities of:
- 5 kN
- 10 kN
- Testing configurations include:
- Uniaxial tensile testing
- Compression testing
- Three-point and four-point bending (beams and structures)
- Compact tension/SENB fracture testing
- Puncture and indentation testing
- Impact testing machines (IZOD) with load capacities of:
- 2, 5, 10, and 20 J
- ASTM-compliant notching equipment with several different notch style
Instrumentation and Measurement
- Axial extensometers and flexometers for accurate strain measurement
- High-resolution DIC up to 300 FPS
- Load-controlled and displacement-controlled testing modes
- Quasi-static mechanical characterization of polymers, composites, and additively manufactured components
Manufacturing-Relevant Evaluation
- Mechanical testing of components produced via:
- Injection molding
- Compression molding
- Additive manufacturing
- Powder-based molding and sintering
- Assessment of stiffness, strength, deformation behavior, and failure modes relevant to structural applications
3. Metrology and Dimensional Evaluation
- Optical microscopes with digital imaging systems
- Manual and automated dimensional metrology including:
- Standard measuring tools
- Coordinate measuring machine (CMM)
- Profile projector
- Dimensional verification of molded, printed, machined, and sintered components
4. Computational and Digital Engineering Capabilities
Engineering Computation and Simulation
- High-performance engineering workstations supporting:
- CAD modeling and digital prototyping
- Finite element analysis (FEA) of structural components
- Topology optimization tools
- Manufacturing process simulation and toolpath development
- GAZEBO and other system simulation tools using LINUX
- Dedicated simulation workstation equipped with:
- Intel 14th-generation multi-core processor
- 64 GB RAM
- Professional-grade GPU acceleration
High-Performance Computing Resources
- Access to Texas A&M High Performance Research Computing (HPRC) facilities, including:
- Nearly 1,000 computational nodes
- Multi-petaflop-class computing capability
- Used for:
- Large-scale parametric studies
- Design space exploration
- Data-driven modeling and optimization of manufacturing systems
Integrated Digital–Physical Workflow
- Support for digital twins linking:
- Manufacturing process parameters
- Material structure evolution
- Mechanical performance outcomes
- Enables rapid iteration between simulation, fabrication, and experimental validation