Additively manufactured heaters for composite autonomous repair
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Author
Unterhofer, S.
Scazzoli, C.
Luyckx, G.
Deriaz, S.
Pejchal, V.
DOI
Abstract
Reusable launch systems place tougher operational requirements on composite structures, demanding rapid inspection, prompt flightworthiness assessment, and efficient refurbishment between missions. Under a European Space Agency (ESA) contract performed in the frame of CSEM, STSFLPP FIRST! Initiative, CompPair, Com&Sens and COMATEC developed a breadboard demonstrator combining CompPair’s proprietary heat-activated self-healing composite with embedded sensing and localized heating in carbon-fi - bre-reinforced polymer (CFRP) laminates, in a configuration representative of reusable launch applications. A key contribution from CSEM was the design and fabrication of additively manufactured ultra-thin metallic heater grids with bespoke geometries, embedded within the CFRP laminate to deliver localized Joule heating and activate repeatable healing of the composite matrix. Damage detection and localization were enabled by an embedded Fibre Bragg grating (FBG) sensing network. Nondestructive evaluation confirmed successful heating grid integration and validated both damage localization and postimpact healing effectiveness.
Publication Reference
CSEM Scientific and Technical Report 2025, p. 59–60
Year
2025