Manufacturing of Smart Structures Using Fiber Placement Manufacturing Processes

Manufacturing of Smart Structures Using Fiber Placement Manufacturing ProcessesMatthew M. Thomas, Robert A. Glowasky, Bruce E. Mcllroy, and Todd A. StoryMcDonnell Douglas AerospaceMcDonnell Douglas CorporationP.O. Box 516, St. Louis, MO 63 166-0516ABSTRACTSmart structures research and development, with the ultimate aim of rapid commercial and military production of thesestructures, are at the forefront of the Synthesis and Processing of Intelligent Cost-Effective Structures (SPICES) program.As part of this ARPA-sponsored program, MDA-E is using fiber placement processes to manufacture integrated smartstructure systems. These systems comprise advanced composite structures with embedded fiber optic sensors, shapememory alloys, piezoelectric actuators, and miniature accelerometers. Cost-effective approaches and solutions to smartmaterial synthesis in the fiber-placement process, based upon integrated product development, are discussed herein.Keywords: smart structure, composites, manufacturing, fiber-optic sensors, shape memory alloy, piezoelectric actuators.1. INTRODUCTIONThe field of smart structures is characterized by a synergy of research areas, previously considered unrelated, to produce anew generation of structures offering both performance and cost benefits. In recent years, numerous researchers havebegun to transition the analytical work that pioneered the interest in smart structures to actual commercial and industrialapplications. One of the new areas of research and development generated by this transition was that involving smart