On June 6, 2025, at the Enzo and Dino Ferrari Circuit in Imola, the Polytechnic University of Bari took part in the event “Racing and High Performance Support Equipment”, organized by AIPnD (Italian Association for Non-Destructive Testing), contributing a technical presentation focused on “NDT and SHM techniques based on thermal methods for material characterization in the automotive industry”.
The presentation, delivered by Ester D’Accardi, researcher of the Structural Diagnostics and Thermal Methods Group of the DMMM Department at the Polytechnic University of Bari, is part of the research activities of the national project CO-SMART, promoted by the Center for Sustainable Mobility (MOST) and funded through PNRR – NextGenerationEU resources.
SHM and thermography: new frontiers for automotive materials
The presentation highlighted innovative methodologies for structural health monitoring (SHM) and non-destructive testing (NDT) of advanced composite materials, with particular focus on 3D-printed components used in the high-performance automotive sector.
Among the techniques discussed, Thermoelastic Stress Analysis (TSA) demonstrated remarkable potential as a non-invasive tool for detecting and monitoring in real time the damage evolution in components subjected to cyclic loading. Special attention was given to the use of low-cost thermal sensors, such as the FLIR BOSON and FLIR Lepton, which represent promising solutions for implementing accessible and scalable monitoring systems, even in demanding operational environments.
Comparing sensors: from the lab to the track
The presented results concerned fatigue tests performed on 3D-printed composite specimens with different laminate configurations (Quasi-Isotropic, Cross-Ply, Angle-Ply), each featuring a central hole designed to trigger crack propagation. During testing, thermographic sequences were acquired and processed for spectral analysis, amplitude mapping, and phase variation, comparing data from high-end cooled infrared cameras with those from compact and cost-effective microbolometric sensors.
The BOSON sensor, in particular, proved highly effective in detecting cracks and delaminations even in the early stages of damage, providing qualitative and quantitative results consistent with those obtained using higher-grade equipment. The Lepton 3.5 sensor, though limited in resolution and frame rate, successfully visualized damage progression during the final fatigue cycles, opening up interesting opportunities for ultra-low-cost rapid screening.
PoliBa and CO-SMART: thermography driving sustainable mobility
In her talk, Ester D’Accardi emphasized how thermography applied to SHM can serve as a practical and efficient resource for continuous monitoring of critical automotive components, particularly in racing and high-performance contexts, where lightweight design, reliability, and diagnostic readiness are essential.
This research falls within the scope of Spoke 11 of the CO-SMART project, dedicated to innovative materials and structural lightweighting, and aims to transfer laboratory technologies into industrial applications, reducing costs and complexity through the adoption of compact and versatile tools.
Through this work, the Polytechnic University of Bari confirms its role as a leading player in applied research for the automotive industry, actively contributing — through CO-SMART — to building a future of smarter, more sustainable, and high-performance mobility.
