Session: ASME Undergraduate Student Design Expo

Paper Number: 173903

Advanced Inspection of 3d-Printed Ultem Aerospace Structures Using Matrix Array Ultrasonic Testing (Maut) 

The increasing use of composite materials such as carbon-fiber reinforced polymers (CFRPs) and high-performance thermoplastics like Ultem in aerospace manufacturing necessitates advanced, non-destructive inspection technologies that can ensure structural integrity while maintaining production efficiency. These high-performance polymer materials provide various advantages (e.g. high strength-to-weight ratio) in structural fabrication of aircraft and aerospace structures such as wind turbine blades which makes them increasingly expand in these industries. Nondestructive testing (NDT) methods have been continuously developed to respond to the quality inspection demand of such materials. Matrix Array Ultrasonic Testing (MAUT) is a next-generation inspection method that delivers high-resolution, real-time imaging capabilities tailored for detecting subsurface flaws in complex geometries. Leveraging a dense matrix of ultrasonic transducers with unmatched pitch resolution (0.25 mm), MAUT enables precise localization and characterization of internal defects such as delaminations, voids, inclusions, and bonding failures, making it ideally suited for the rigorous demands of aerospace engineering.

This study explores the application of MAUT for evaluating the quality and structural integrity of 3D-printed aerospace components fabricated from Ultem, a high-performance thermoplastic widely used for its mechanical strength and thermal resistance. Components and bonded assemblies were produced using additive manufacturing techniques and were subjected to both traditional ultrasonic inspection and MAUT. Bonding interfaces between structural elements were intentionally seeded with artificial defects to assess the capability of MAUT in detecting manufacturing flaws that could compromise performance.

The MAUT system used in this investigation is lightweight, portable, and field-ready. It features real-time C-scan imaging, onboard defect recognition, and remote calibration capabilities, making it highly effective for both production and maintenance environments. The inspection process demonstrated rapid setup, minimal user training requirements, and enhanced accuracy in flaw detection compared to conventional Phased Array Ultrasonic Testing (PAUT). In addition, MAUT’s Industry 4.0 readiness allows for seamless integration with digital inspection records and predictive maintenance platforms.

Results showed that MAUT consistently identified bonding and structural defects with higher resolution and confidence than traditional methods, highlighting its potential for deployment in both manufacturing quality control and in-service inspection of critical aerospace components. The system’s performance, combined with OEM approvals from major manufacturers such as Boeing and Airbus, confirms its suitability for operational integration across the aerospace supply chain.

In summary, MAUT represents a significant advancement in ultrasonic nondestructive evaluation for composite and additive-manufactured aerospace structures. Its demonstrated precision, portability, and digital capabilities make it a powerful tool for ensuring airworthiness, reducing inspection cycle times, and supporting the evolving needs of aerospace engineering and certification.

Presenting Author: Josie Gunter Georgia Southern University

Presenting Author Biography: Josie Gunter is a sophomore mechanical engineering student at Georgia Southern University and an undergraduate research assistant in the LANDTIE Lab. Her current research focuses on the application of advanced nondestructive testing methods to evaluate the structural integrity of composite and additive-manufactured aerospace components. She is specifically studying Matrix Array Ultrasonic Testing (MAUT) for its effectiveness in detecting subsurface flaws and bonding defects in 3D-printed Ultem structures. Josie is an active member of the American Society for Nondestructive Testing (ASNT), the American Society of Mechanical Engineers (ASME), and the Society of Women Engineers (SWE), and currently serves as president of the ASME chapter at Georgia Southern. Her interests include developing inspection solutions that enhance quality assurance in aerospace manufacturing and support the integration of digital tools in engineering applications.

Authors:

Josie Gunter Georgia Southern University
Hossein Taheri Georgia Southern University