3D printing of continuous fiber-reinforced thermoset composites

He, Xu; Ding, Yuchen; Lei, Zepeng; Welch, Sam; Zhang, Wei; Dunn, Martin L.; Yu, Kai

doi:10.1016/j.addma.2021.101921

Cited by 52 publications

(40 citation statements)

References 46 publications

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“…DIW‐printed continuous fiber‐reinforced composites show great promise in high‐performance applications because it allows the processing of thermosetting polymers with high strength and stiffness. [ 80 ] The extruded thermosetting filaments can be cured by applying UV light for UV‐curable resins or transferring the filaments into an oven for thermally curable resins. Till now, there are few reports on the development of DIW‐printed continuous fiber‐reinforced composites due to the limitations of the printer design for the curing process.…”

Section: Direct Ink Writingmentioning

confidence: 99%

3D‐Printed Anisotropic Polymer Materials for Functional Applications

et al. 2021

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Anisotropy is the characteristic of a material to exhibit variations in its mechanical, electrical, thermal, optical properties, etc. along different directions. Anisotropic materials have attracted great research interest because of their wide applications in aerospace, sensing, soft robotics, and tissue engineering. 3D printing provides exceptional advantages in achieving controlled compositions and complex architecture, thereby enabling the manufacture of 3D objects with anisotropic functionalities. Here, a comprehensive review of the recent progress on 3D printing of anisotropic polymer materials based on different techniques including material extrusion, vat photopolymerization, powder bed fusion, and sheet lamination is presented. The state‐of‐the‐art strategies implemented in manipulating anisotropic structures are highlighted with the discussion of material categories, functionalities, and potential applications. This review is concluded with analyzing the current challenges and providing perspectives for further development in this field.

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Section: Direct Ink Writingmentioning

confidence: 99%

3D‐Printed Anisotropic Polymer Materials for Functional Applications

et al. 2021

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“…The filament materials used in 3D printing have various types with multifunction applications [10][11][12]. Several researchers used natural fiber as filament materials made of Flax, Jute, Kenaf Coir, Cotton Wood, Bamboo, and Hemp as the filament materials [10], where He et al [13] used carbon fiber and special ink as filaments to create fiber-based composites. Furthermore, in terms of polymer-based materials, Fu et al [14] summarized the materials used for 3D printing.…”

Section: J O U R N a L P R E -P R O O Fmentioning

confidence: 99%

“…Several researchers used natural fiber as filament materials made of Flax, Jute, Kenaf Coir, Cotton Wood, Bamboo, and Hemp as the filament materials [ 10 ], where He et al. [ 13 ] used carbon fiber and special ink as filaments to create fiber-based composites. Furthermore, in terms of polymer-based materials, Fu et al.…”

Section: Introductionmentioning

confidence: 99%

Model optimization and performance evaluation of hand cranked music box base structure manufactured via 3D printing

Alfarisi

Santos

Norcahyo

et al. 2021

Heliyon

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A sound produced from the music box could mesmerize music lovers. The complex mechanism that combined manual with semi-automatics movement creates the music box as a challenge for the manufacturer to innovate and optimize. This study focused on redesigning a hand-cranked music box's base structure using 3D printing and comparing the sound produced with the original model. It is shown that 3D printing can create a complex model with minimum material waste and good repeatability. After remodeling the music box's in a 3D CAD model, the prototype was built, and the tune played by each model was recorded and compared. The results showed that four improvements were made in the barrel mounting, crankshaft holder, crankshaft locker, and comb locker from the built four models. The sound analysis shows that the quality of sound can be improved by using the system's spacer. Furthermore, the finite element method and exact experiment results show that the loudest and best sound quality can be achieved using a 60° angle slope for the music box base structure.

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“…The major challenges in the additive manufacturing and repair of thermoset‐matrix fiber composites are the extensive curing time as well as the immense energy associated with high temperature and pressure. The frontal polymerization technique is one of the trending techniques among various methods (e.g., reactive extrusion, 4 microwave curing, 5 UV photocuring, 6 pre‐print or post‐print oven curing 7–10 ) to address these challenges. Specifically, the frontal polymerization is a self‐propagation reaction caused by exothermic polymerization, where a “cure front” is formed by a local thermal stimulus that propagates through the material 11–14 .…”

Section: Introductionmentioning

confidence: 99%

Modeling the through‐thickness frontal polymerization of unidirectional carbon fiber thermoset composites: Effect of microstructures

Wang

2022

J of Applied Polymer Sci

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The frontal polymerization is a technique that creates a self-sustaining "cure front" that propagates through the thermoset resin material. Such a technique is potentially capable of substantially reducing the curing time of thermoset resin fiber composites from several hours to only a few minutes or even seconds, which is promising for the additive manufacturing and repair of thermoset fiber composites. In this study, the effect of the microstructures (i.e., fiber volume fraction, fiber tow size, and fiber tow shape) of unidirectional fiber composites on the frontal polymerization initiated in the through-thickness direction of the composites is investigated through computational modeling. The computational model is verified through comparisons with experimental data. The simulation results show that the frontal polymerization process is largely affected by the fiber volume fraction and the fiber tow shape and is insensitive to the fiber tow size. The average front velocity decreases significantly as the fiber volume fraction increases from 0% to 30% and then decreases mildly from 30% to 46%. Above 46%, the average front velocity plateaus. Moreover, the average front velocity decreases in an approximately linear fashion as the ratio between the major radius and minor radius of the elliptical cross section of fiber tow increases.

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3D printing of continuous fiber-reinforced thermoset composites

Cited by 52 publications

References 46 publications

3D‐Printed Anisotropic Polymer Materials for Functional Applications

3D‐Printed Anisotropic Polymer Materials for Functional Applications

Model optimization and performance evaluation of hand cranked music box base structure manufactured via 3D printing

Modeling the through‐thickness frontal polymerization of unidirectional carbon fiber thermoset composites: Effect of microstructures

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