Nowadays, the additive manufacturing of multifunctional materials is booming. The fused deposition modeling (FDM) process is widely used thanks to the ease with which multimaterial parts can be printed. The main limitation of this process is the mechanical properties of the parts obtained. New continuous-fiber FDM printers significantly improve mechanical properties. Another limitation is the repeatability of the process. This paper proposes to explore the feasibility of printing parts in continuous carbon fiber and using this fiber as an indicator thanks to the electrical properties of the carbon fiber. The placement of the fiber in the part is based on the paths of a strain gauge. The results show that the resistivity evolves linearly during the elastic period. The gauge factor (GF) increases when the number of passes in the manufacturing plane is low, but repeatability is impacted. However, no correlation is possible during the plastic deformation of the sample. For an equivalent length of carbon fiber, it is preferable to have a strategy of superimposing layers of carbon fiber rather than a single-plane strategy. The mechanical properties remain equivalent but the variation in the electrical signal is greater when the layers are superimposed.

The interconnection between engineering simulations, real-world experiments, and virtual reality remains underutilised in engineering. This study addresses this gap by implementing such interconnections, focusing on active thermography for a carbon fibre plate in the aerospace domain. Six scenarios based on three parameters were simulated using ComSol Multiphysics 6.2 and validated experimentally. The results were then integrated into a virtual reality serious game developed with Unreal Engine 5.3.2 and aimed at educating users on thermography principles and aiding rapid experimental condition analysis. Users are immersed in a 3D representation of the research laboratory, allowing interaction with the environment, understanding thermographic setups, accessing instructional videos, and analysing results as graphs or animations. This serious game helps users determine the optimal scenario for a given problem, enhance thermography principle comprehension, and achieve results more swiftly than through real-world experimentation. This innovative approach bridges the gap between simulations and practical experiments, providing a more engaging and efficient learning experience in engineering education. It highlights the potential of integrating simulations, experiments, and virtual reality to improve understanding and efficiency in engineering.

This paper deals with the numerical modelling of non-destructive testing of composite parts using active thermography. This method has emerged as a new approach for performing non-destructive testing (NDT) on continuous carbon fibre reinforced thermoplastic polymer (CCFRTP) components, particularly in view of detecting porosity or delamination. In this context, our numerical model has been developed around references containing internal defects of various shapes and sizes. The first novelty lies in the fact that the heat source used in the experimental setup is modelled exhaustively to accurately model the radiation emitted by the lamp, as well as the convection and conduction around the bulb. A second novelty concerns the modelling of the CCFRTP making up the benchmark used. Indeed, its thermal properties vary as a function of the sample temperature. Therefore, the actual thermal properties have been experimentally measured and were later used in our model. The latter then captures the material dependency on temperature. The results obtained by our model proved to be in close agreement with the experimental results on real reference points, paving the way for future use of the model to optimise experimental configurations and, in particular, the heating parameters.

Additive Manufacturing (AM) allows to reduce the industrialization step by eliminating or minimizing the tools conception phase, process development,… These technologies permit now to produce real parts with required mechanical properties. AM technologies allow new ways of thinking by unlocking the design limitations encountered by other manufacturing methods. The Electron Beam Melting (EBM) technology is a powder-bed-metal based additive manufacturing technique developed at Chalmers University of technology in the late 1990’s and commercialized by the Swedish company ARCAM AB in the early 2000’s. The most widely used material for the EBM Process is Ti6Al4V. This is the material used in this study with standard processing parameters. EBM process is a near net shape process and it is necessary to carry out finishing operation after EBM. The goal of this research is to analyze the impact of chemical etching on parts produced by electron beam melting. Given that the surface conditions are poor (Ra between 25 to 35 µm), an enhancement of these is asked. Dimensional and surface measurements were realized on conceived parts. Different exposure times were tested. The impact of these times on surface quality was evaluated. To help predicting the excess thickness to be provided, the dimensional impact of chemical polishing on EBM parts was estimated. 36 parts were measured before and after chemical machining. The improvement of surface quality was also evaluated after each treatment.