The University of Maine’s Advanced Structures and Composites Center (ASCC) continues to cement its reputation as a leader in cutting-edge research with the recent recognition of its paper, Novel Field-Manufacturing Methods for Long-Fiber Thermoplastic Composites, as a winner of the 2024 CAMX Outstanding Technical Paper Award for Best in Track: Manufacturing & Processing Technologies. This honor, presented at the Composites and Advanced Materials Expo (CAMX) in San Diego, California, celebrates innovative research that advances the composites and advanced materials industries.
Authored by ASCC researchers James Haller, Jacob Clark, James Gayton, Michael Hunter, Andrew Schanck, Cody Sheltra and UMaine professors William Davids, Roberto Lopez-Anido and Justin Lapp, the paper addresses a key challenge in the adoption of continuous fiber-reinforced thermoplastics (CFRTPs): their complex fabrication. These materials are highly valued for their strength-to-weight ratio, recyclability and corrosion resistance, making them an ideal candidate for sustainable construction and infrastructure applications.
The researchers introduced several manufacturing processes, including the Continuous Forming Machine (CFM) — an ASCC-patented pultrusion platform that more efficiently produces structural profiles like rods, plates and channels that are lightweight and corrosion resistant. The team also developed localized thermoforming techniques that allow CFRTP panels to be adapted onsite for infrastructure needs. These advancements demonstrate the potential for CFRTPs to revolutionize sustainable construction by enabling efficient, field-friendly manufacturing.
This research addresses a critical challenge in the construction and infrastructure industries: the limitations of traditional materials and thermoset fiber-reinforced polymers. Manufacturing hurdles associated with thermoplastics have prevented their widespread adoption, despite their advantages such as recyclability, long shelf life, and superior impact resistance. These challenges have created a pressing need for innovative materials and processes that balance performance, sustainability, and practicality.
“CFRTP materials offer additional advantages over thermosets in terms of sustainability, recyclability, and an ability to be reformed for adaptation to on-site applications,” said Haller.
Dr. Habib Dagher, Executive Director of ASCC added, “The advanced manufacturing innovations being performed at the ASCC are helping reduce manufacturing barriers for Continuous Fiber-Reinforced Thermoplastic materials, and their applications in sustainable construction and civil infrastructure.”
The CFM and localized thermoforming techniques enable the efficient production and field-friendly adaptation of long-fiber thermoplastic composites, making it possible to create structural components such as concrete reinforcing bars and complex shapes that are recyclable, durable and environmentally friendly. By overcoming manufacturing barriers, this research not only advances the potential of CFRTPs in construction but also aligns with global sustainability goals, paving the way for more resilient, eco-conscious infrastructure.
CAMX described the award as recognizing “well-written, engaging, and groundbreaking papers addressing critical areas of importance to the composites and advanced materials industry.” The paper’s success underscores the ASCC’s commitment to advancing sustainable materials and innovative processes that have real-world impacts.
This paper was also featured in the January/February issue of the SAMPE Journal, a special edition focused on thermoplastic composites. This recognition reflects the ASCC’s ongoing pursuit of excellence in research, as well as UMaine’s leadership in sustainable innovation.
As the largest university-based research center in Maine, the ASCC has consistently led the charge in composites innovation, contributing to transformative projects such as floating offshore wind platforms, advanced recycling for wind turbine materials and infrastructure renewal. The center’s achievements highlight UMaine’s national and international leadership in research and education, advancing solutions for the most pressing challenges in sustainability and engineering.
