The manufacture of composite structures with a built-in network of piezoceramics

A manufacturing method was developed for integrating a network of distributed piezoceramic actuators/sensors onto laminated carbon/epoxy composite structures. The network of built-in actuators/sensors is used to monitor the health of the host composite structure by acquiring information about the condition of the structure throughout its service life. The manufacturing method applies the printed circuit technique to fabricate a thin flexible layer with a network of piezoceramics. It is used as an extra ply that is either inserted into or bonded onto the surface of a composite laminate to give it actuating and sensing capabilities. This layer that provides the added functionality is referred to as the “SMART Layer” (Stanford Multi-Actuator-Receiver Transduction Layer). Using the developed method, several SMART Layer prototypes have been fabricated and embedded inside carbon fiber composite laminates successfully. Tests were conducted on composite panels integrated with the SMART Layer to validate the design and the manufacturing procedure.