Convergent Manufacturing for Next-Generation High-Rate Composite Manufacturing

Abstract:  

The growing demand for lightweight, high-performance composite structures across the energy, aerospace, defense, transportation, and infrastructure sectors is driving the need for faster, more cost-effective manufacturing. Meeting these demands requires more than improving individual processes, it requires a convergent manufacturing approach that integrates advanced materials, manufacturing processes, automation, digital technologies, and intelligent manufacturing into a unified production ecosystem. This seminar will discuss how convergent manufacturing is enabling the next generation of scalable high-rate composite manufacturing by combining technologies such as additive manufacturing, compression molding, thermoforming, automated fiber placement, filament winding, robotics, advanced sensing, and nondestructive evaluation. Rather than optimizing individual processes in isolation, this approach leverages the strengths of multiple manufacturing technologies to improve productivity, quality, and performance. Examples from Oak Ridge National Laboratory will highlight recent advances, including Additive Manufacturing–Compression Molding (AM-CM), Additively Reinforced Thermoforming (ART), additive manufacturing-assisted filament winding, and integrated nondestructive evaluation. The talk will conclude with a vision for the future of composite manufacturing, where convergent manufacturing serves as the foundation for agile, autonomous, and data-driven production systems capable of delivering resilient manufacturing solutions for the nation’s most demanding applications.

Bio:

Dr. Ahmed Arabi Hassen is the Group Leader of the Composites Innovation Group and a Senior R&D Staff Scientist at Oak Ridge National Laboratory’s (ORNL) Manufacturing Science Division and Manufacturing Demonstration Facility (MDF). He leads multidisciplinary research in convergent manufacturing, advanced composites, large-format additive manufacturing (LFAM), digital manufacturing, and intelligent manufacturing systems, with a focus on developing scalable, high-rate manufacturing technologies for energy, aerospace, defense, transportation, and infrastructure applications. Dr. Hassen has pioneered several advanced manufacturing technologies, including hybrid additive manufacturing processes, high-rate composite manufacturing, composite tooling, and digital qualification approaches that accelerate the transition of innovative manufacturing technologies from laboratory research to industrial deployment. His research has resulted in numerous commercialized technologies, industry partnerships, and licensed patents that have helped establish new markets for LFAM and advanced composite manufacturing. He has authored more than 150 technical publications, holds 24 granted and pending patents, and has successfully led multi-million-dollar research programs sponsored by the U.S. Department of Energy and industry. His contributions have been recognized through three R&D 100 Awards, the SME Jud Hall Composites Manufacturing Award, multiple ACMA ACE Awards, and numerous innovation awards. Dr. Hassen is an ASNT Fellow, and previously served on the ASNT Board of Directors, chaired the ASNT Research Symposium, and held several national leadership positions advancing nondestructive testing and advanced manufacturing technologies.