This presentation will describe a novel design and fabrication of a wear sensor that can be additively manufactured using a variety of electronic printing methods for in-situ monitoring of wear and abrasion of materials. The sensor design incorporates a circuit with closely spaced and narrow interconnect traces connected to a set of parallel resistors. The entire design can be printed conformal to the surface or embedded into a material to detect the depth of the groove generated during abrasion of the material. The presentation will additionally include high resolution sensor designs enabled by additive manufacturing as well as implementation for wireless and passive operations of the embedded sensor.

Sameh Dardona received the B.S. degree from Birzeit University, West Bank, Palestine, in 1998, the M.S. degree from Temple University, Philadelphia, PA, USA, in 2002, and the Ph.D. degree from the Georgia Institute of Technology, Atlanta, GA, USA, in 2006, all in applied physics. He joined the United Technologies Research Center (UTRC), in 2006 as a senior research scientist and is currently an associate director for research and innovation. He is leading the printed electronics initiative with responsibly for the design and fabrication of additively manufacturable sensors. His research interests include electronics additive manufacturing, advanced and embedded sensors, sensor network, physics-based device modeling, and designs for additive manufacturing.

United Technologies Research Center (UTRC), the corporate research center for United Technologies Corporation, is headquartered in East Hartford, CT. UTRC plays a key role as the corporation's innovation engine, focusing on advanced technologies. The center employs approximately 600 research scientists, engineers, and support staff (85% of technical staff have advanced degrees). UTRC performs basic, applied and exploratory research in a broad spectrum of technologies including chemical sciences, fluid mechanics, electronics materials and structures, information technology, and systems technology. The center has component and system level modeling tools, material development laboratories, fabrication and characterization laboratories, and combustion test facilities for component and prototype system testing.