Rapid manufacture of integrated self-powered sensing systems using additive manufacturing for critical structure health monitoring

In this project, the feasibility of rapid manufacturing of integrated corrosion monitoring sensing systems within critical engineering structural components using advanced AM technologies has been demonstrated with an exemplar model structure of crevice corrosion monitoring with integrated carbon-based electrochemical sensors. Corrosion performance of all five different materials model crevice former structures built using different AM technologies have been investigated for the first time in a 3.5% NaCl test solution, and the tests results provide the guidelines for the selection of appropriate AM technologies for rapid manufacturing engineering structures in corrosive environment applications. The model crevice corrosion monitoring structure and the rapid manufacturing approaches achieved in this project also provide proof of the concept for design and rapid manufacturing of functionalised engineering components with self-powered embedded structural health monitoring devices.