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Research

The AMCODE Lab conducts research at the intersection of additive manufacturing, composite structures, and design engineering for aerospace and advanced manufacturing applications. Our work focuses on developing technologies that are not only novel, but also manufacturable, repairable, inspectable, and relevant to real engineering systems.

AMCODE’s distinguishing capability is the integration of materials processing, robotic manufacturing, digital process control, and aerospace design validation within a single laboratory workflow. This allows the lab to move from material and process development to structural demonstration, repair workflow development, and student-built aerospace systems.

The lab’s research portfolio connects materials, processes, automation, digital manufacturing, and systems design. Projects range from continuous fiber additive manufacturing and large-format composite tooling to thermoplastic composite joining, automated repair, CubeSat development, and design-build-test aerospace systems.

Core Research Areas

Additive Manufacturing

We develop additive manufacturing methods for aerospace structures, composite tooling, repair, and process automation. Current work includes continuous fiber 3D printing, robotic large-format extrusion, pellet-based additive manufacturing, process monitoring, and digital-twin-enabled manufacturing workflows.

  • Fusion or extrusion AM
  • Thermosets and thermoplastics
  • Gantry and robotic (3 to 7-axis) 
  • Non-planar printing 
  • Desktop to large format
  • In process monitoring
  • Automated fiber placement (AFP)
  • End effectors 
  • Reactive AM (REAM/RAM)

Composites

We study composite materials and structures with emphasis on thermoplastic composites, induction welding, repair, impact damage, structural performance, multifunctional composites, and aerospace tooling. A major objective is to improve how composite structures are manufactured, joined, inspected, repaired, and sustained.

  • VARTM, layup, comp. molding
  • Functional composites
  • Structural batteries
  • Continuous fiber filaments
  • Tow impregnation & sizing
  • Fiber pultrusion & impregnation
  • Process simulation & integration
  • Structural analysis & design
  • Composite characterization

Design Engineering

We apply design engineering methods to aerospace systems, aircraft design, CubeSats, robotic manufacturing, and repair workflows. This work emphasizes design for manufacturing, design for repair, trade studies, prototyping, and validation of systems that must operate under real constraints.

  • Multi-discip. Design Optimization
  • Rapid prototyping
  • Performance simulation
  • Process integration
  • Automation research
  • System and process prototypes
  • Rotorcraft & aircraft design
  • Advanced air mobility
  • Equipment prototypes

Research Thrust Areas

1. Hybrid Additive-Subtractive Large Format Continuous Fiber and Metal Manufacturing

AMCODE’s roadmap in hybrid additive-subtractive automation-driven manufacturing integrates large-format extrusion, continuous fiber deposition, and CNC finishing within a coordinated automation framework. Applied to structural-scale composite tooling, molds, and load-bearing components, combining high-deposition thermoplastics with orientation-controlled reinforcement and precision machining.

2. Space Mission Design, In-Space Assembly & Manufacturing (ISAM) 

AMCODE’s architectural roadmap toward ISAM and ISRO, In-situ Resource Utilization, centers around small-sats. The work includes configuration design, AM Payload design and integration. The program serves as space engineering capacity building, with the goal of putting AMCODE and South Carolina on the space map.

Publications and Technical Outputs

AMCODE research produces peer-reviewed publications, conference papers, patents, technical demonstrations, student-led projects, and externally funded research outcomes. Publications and technical outputs reflect the lab’s emphasis on practical aerospace manufacturing, composite structures, repair technologies, and design methods.

Research Philosophy

The lab prioritizes research that bridges the gap between early-stage concepts and deployable engineering capability. We are especially interested in problems where manufacturing constraints, material behavior, automation, structural performance, and lifecycle sustainment must be considered together.

Our goal is to train students and develop technologies that advance aerospace manufacturing and structural systems from concept to prototype, from prototype to validated process, and from validated process toward practical implementation.