3D-Printing Improves Lightning Strike Protection

Researchers from Oak Ridge National Laboratory are using a new 3D printing technique to improve lightning strikes on airplanes. Airplane exteriors sare traditionally made of carbon fiber reinforced plastic (CFRP). It's lighter than metal, but its low electrical conductivity and heat resistance make it vulnerable to lightning strikes. Conventional lightning strike protection technology includes expanded metal foils/films on top of composite structures. This technology works, but it increases weight, corrosion, and it's expensive to add and repair. Oak Ridge researchers created a new adhesive material for carbon fiber reinforced plastic (CFRP), and the material has proven effective against lightning strikes. The polymer has a chain-like structure that makes the aircraft components both electrically conductive and structurally strong with thermal treatment. It's applied in thin layers from 0.25–0.4 mm thickness.Now comes the fun part. The research team had to test it, so it conducted simulated lightning strike tests on the protected components. The pieces not only showed minimal damage but also enabled more uniform heat dissipation, suggesting that it could eventually lead to more effective lightning strike protection technology.