MAE Seminar- The Future of Advanced Composites Manufacturing Using Natural Fibers

Dr. Daniel Walczyk, PhD, PE is a Professor of Mechanical Engineering and Director of the Manufacturing Innovation Center at Rensselaer Polytechnic Institute (RPI). He holds college degrees from MIT (PhD ’95), RPI (MS ’91), Syracuse University (BS ’86), and Onondaga Community College (AS ’84), all in mechanical engineering, and did a post-doc position at the Technical University at Aachen (Germany) in 1995. Dr. Walczyk also worked in industry as mechanical engineer and machine designer for a total of seven years in the Syracuse area prior to graduate work. While at RPI, Dr. Walczyk’s research has generally been focused on new manufacturing processes, rapid tooling and fixturing, and additive manufacturing. Since the early 2000’s, one of his primary R&D areas has been advanced composites manufacturing for both synthetic and bio-based materials. In addition to a many related publications and patents, his research activity has resulted in two spin-off companies, Vistex Composites, LLC and InSitu Composites, LLC, both of which are focused on synthetic materials. His talk today looks at the necessity and requirements for moving industry towards biocomposites.

Abstract:  Advanced composite materials made from non-renewable resources, available since the 1930’s, are used in a variety of industries including, but not limited to transportation, aerospace and defense, wind energy, sporting goods, electrical and electronics, and infrastructure. Despite their favorable physical and mechanical properties, advanced composites suffer from poor end-of-life options. This has led to renewed interest in composite materials from renewable sources, aka biocomposites. In this seminar, Dr. Walczyk will talk about the current state and future of biocomposites manufacturing with a particular focus on natural fibers. The discussion will begin with how hemp and flax, the two strongest fibers available domestically, are grown, harvested, decorticated (separate fiber and hurd/shive), degummed, and prepared for use in a composite material system. After reviewing currently available bio-based thermoset and thermoplastic resins, the different manufacturing processes used for producing biocomposite parts will be reviewed and assessed. Finally, an overview of research in Dr. Walczyk’s lab related to processing of bast fiber plants (e.g., hemp, flax) and manufacturing of biocomposites for a variety of commercial applications will be presented.