The goal of this program is to demonstrate the use of 3D printing to print multifunctional data cables and connections. A new type of 3D printing, Ultrasonic Additive Manufacturing (UAM), allows for thermal elements, electrical elements, structural elements, fiber optics, and radiation shielding to be printed into a single monolithic build. By combining three functions (fiber optics, copper wires, and radiation shielding) it will be shown that a lighter weight, higher performance solution can be customized with limited manual labor. Furthermore, such ribbon cables should provide a tighter bend radius than standard twisted pair alternatives. The success of Phase I will be measured by the teams ability to effectively answer the following key questions: Can multiple features successfully be embedded in a single cable? What commercial off the shelf (COTS) connectors can be utilized in a 3D printed solution? How do 3D printed cables compare to traditional hand-built solutions? What is the most robust connection for transitioning from 3D printed cables to other devices?
