Printed multifunctional skin for aerodynamic structures, and associated systems and methods

1. A method of manufacturing an aerodynamic structure, comprising:

providing a first aerodynamic structure having a first surface exposed to an outside environment, and a second surface facing a second aerodynamic structure;

printing a sensor over the first surface of the first aerodynamic structure;

printing conductive traces over the first surface of the first aerodynamic structure, wherein the conductive traces electrically connect the sensor to electronics; and

protecting the electronics against environment by attaching the second aerodynamic structure to the first aerodynamic structure, wherein the second aerodynamic structure has a third surface exposed to the outside environment, and a fourth surface facing the first aerodynamic structure, and wherein the electronics are housed between the second surface of the first aerodynamic structure and the fourth surface of the second aerodynamic structure.

2. The method of claim 1 , further comprising:

placing an actuator over the first surface of the first aerodynamic structure; and

electrically connecting the actuator to the electronics with the conductive traces.

3. The method of claim 1 , wherein the aerodynamic structure is an element of a pump, a wind turbine, an air fan, a submarine, a ship, an engine, a prosthetics, or a pipeline.

4. The method of claim 1 , further comprising:

printing the sensor by an electronics printer.

5. The method of claim 2 , further comprising:

printing the sensor and the actuator over a foil by an electronics printer using additive manufacturing; and

adhering the foil to the first surface of the first aerodynamic structure.

6. The method of claim 2 , wherein the sensor and the actuator are less than 100 μm thick.

7. A method of controlling an aircraft, comprising:

receiving first data from a sensor by an IC chip;

processing the first data by the IC chip to generate second data;

sending the second data to an actuator by the IC chip;

actuating the actuator based on the second data from the IC chip, wherein the sensor and the actuator are carried by a first surface of a first aircraft structure of the aircraft, herein the sensor and the actuator are printed on the first aircraft structure of the aircraft, wherein the first aircraft structure is exposed to an outside environment, and wherein the first aircraft structure comprises a second surface facing a second aircraft structure; and

protecting the IC chip against environment by attaching the second aircraft structure to the first aircraft structure, wherein the second aircraft structure has a third surface exposed to the outside environment, and a fourth surface facing the first aircraft structure, and wherein the IC chip is housed between the second surface of the first aircraft structure and the fourth surface of the second aircraft structure.

8. The method of claim 7 , wherein the sensor is a pressure sensor, and the actuator is an ionic wind generator for boundary layer control.

9. The method of claim 8 , wherein the pressure sensor comprises sintered micro-scale lead zirconate titanate (PZT).

10. The method of claim 7 , wherein the sensor and the actuator are printed over a foil by an electronics printer by additive manufacturing, and wherein the foil is adhered to the first surface of the first aircraft structure.

11. The method of claim 7 , wherein the sensor and the actuator are printed over the first surface of the first aircraft structure by additive manufacturing.

12. The method of claim 7 , wherein the sensor is selected from a group consisting of a pressure sensor, a temperature sensor, a heat flux sensor, a strain sensor, an ice sensor, a strain transducer, and an RF antenna; and the actuator is selected from a group consisting of a heater, an ionic actuator, a plasma actuator, and a miniature air blower.

13. An aerodynamics structure, comprising:

a first aerodynamic structure having a first surface exposed to an outside environment, and a second surface facing a second aerodynamic structure; and

a printed sensor carried by the first surface of the first aerodynamic structure;

at least one printed conductive trace over the first surface of the first aerodynamic structure;

a second aerodynamic structure having a third surface exposed to the outside environment, and a fourth surface facing second surface of the first aerodynamic structure; and

electronics connected to the printed sensor through the at least one printed conductive trace, wherein the electronics is configured and protected in a space between the second surface of the first aerodynamic structure and the fourth surface of the second aerodynamic structure.

14. The device of claim 13 , further comprising a printed actuator carried by the first surface of the first aerodynamic structure.

15. The device of claim 14 , wherein the aerodynamic structure is an aircraft structure.

16. The device of claim 15 , wherein the actuator is a heater at a leading edge of the aircraft structure, and the printed sensor is a strain sensor downstream from the printed actuator.

17. The device of claim 14 , wherein the aerodynamic structure is an element of a pump, a wind turbine, an air fan, a submarine, a ship, an engine, a prosthetics, or a pipeline.

18. The device of claim 15 , wherein the aircraft structure is an unmanned airplane.

19. The device of claim 13 , wherein the printed sensor is less than 10 μm thick.

20. The device of claim 14 , wherein the printed sensor and the printed actuator are less than 100 μm thick.

21. The device of claim 14 , further comprising:

an adhesive layer attached to the outer surface of the aerodynamic structure;

a foil attached to the adhesive layer, wherein the foil carries the printed sensor and the printed actuator.

22. The method of claim 1 , wherein the aerodynamic structure is an unmanned airplane.

23. The method of claim 7 , wherein the aircraft is an unmanned airplane.

24. The device of claim 13 , wherein the aerodynamic structure is an unmanned airplane.