Embeddable Multi-Material Wireless Micro-Sensors Utilizing Additive Manufacturing and Enhanced Microstructure

<p>The development of embeddable, multi-material wireless microsensors offers transformative potential for structural health monitoring (SHM) in aerospace applications. This work integrates additive manufacturing (AM) techniques with advanced microstructural design to produce flexible, high-resolution sensors that can be directly embedded into polymer substrates. By utilizing the vat photopolymerization process, customized embedded sensors are seamlessly integrated into polymer AM structures. These sensors are then continuously refined, targeting increases in performance, both internal and external. Microstructural enhancements are explored to modify the rheological properties of the fabricated embedded sensing channels and enhance the adhesive bonding between the embedded sensor and the AM structure. Analytical modeling characterizes these advancements and provides the tools necessary to make informed design decisions for future complex sensing applications. Then, the concepts applied to polymer sensors are expanded to ceramic substrates. Design alterations then enable the fabrication of wireless embedded thermal ceramic sensor systems. The addition of multi-material fabrication techniques consequently enables the fabrication of long range wireless strain ceramic sensing systems. These results collectively establish a robust framework for designing and deploying customizable, embeddable microsensors, enabling in-situ monitoring of deformation and temperature, and successfully demonstrating the overall viability of embedded sensors for real-world aerospace sensing applications, as well as potential avenues for further SHM advancements built upon this work.</p>

Name thesis:degree_name

Doctor of Philosophy in Aerospace Engineering

Level thesis:degree_level

Dissertation - Open Access

Discipline thesis:degree_discipline

Aerospace Engineering

Year

2025

Author dc:creator

• Reed, Nicholas

• Additive Manufacturing
• Sensing
• SHM
• Microstructure
• Embedded Sensing
• Structures and Materials

Repository record dc:identifier

https://commons.erau.edu/edt/919

OAI identifier oai:identifier

oai:commons.erau.edu:edt-1956