A Mechanical Performance Study of Dual Cured Thermoset Resin Systems 3D-Printed with Continuous Carbon Fiber Reinforcement

Rahman, Atikur; Hall, Eric; Gibbon, Luke; Islam, Md. Zahirul; Ulven, Chad A.; Scala, John J. La

doi:10.3390/polym15061384

Cited by 15 publications

(3 citation statements)

References 45 publications

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“…Based on the analysis and research of the above curing process parameters, the composite was prepared under −0.09 MPa vacuum degree, 80 min impregnation time and 165°C curing temperature. The flexural strength and modulus of the composite reached 482.89 MPa and 35.11 GPa, respectively, and compared the flexural properties with the 3D printed CCF reinforced polymer composites (CCFRPCs) in literature 21,22,34‐40 . The flexural properties of the 3D printed composites are plotted as shown in Figure 11.…”

Section: Resultsmentioning

confidence: 99%

“…Based on the analysis and research of the above curing process parameters, the composite was prepared under À0.09 MPa vacuum degree, 80 min impregnation time 21,22,[34][35][36][37][38][39][40] The flexural properties of the 3D printed composites are plotted as shown in Figure 11. It can be found that the 3D printed composites in this paper show better flexural properties, which are significantly better than most existing 3D printed CCFRPCs.…”

Section: Demonstration Of 3d Printed Ccfrtcsmentioning

confidence: 99%

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Investigation on the mold‐less curing process of 3D printing continuous carbon fiber reinforced thermoset composites based on thermoplastic shells constraint

Zhao,

Wang,

Duan

et al. 2023

Polymer Composites

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To overcome the dependence of continuous carbon fiber reinforced thermoset composites (CCFRTCs) on molds during the curing, a thermoset continuous fiber prepreg filament and thermoplastic filament alternate printing method was proposed. CCFRTCs with thin thermoplastic shells were prepared based on the method, and the confinement of thermoplastic shells enabled the mold‐less curing of CCFRTCs. The influence of key curing process parameters on the flexural properties of the specimens was systematically investigated. The experimental results showed that the flexural properties of the prepared composites were correlated positively with the vacuum degree and showed a tendency of first increasing and then decreasing with the increasement of impregnation time and curing temperature. Through x‐ray computed tomography (CT) and scanning electron microscope (SEM) analysis, the effect of key curing process parameters on the flexural properties of the CCFRTCs was clarified. Under the guidance of suitable curing process parameters, the flexural strength and modulus of the composite reached 482.89 MPa and 35.11 GPa, which were significantly better than most existing 3D printed continuous carbon fiber reinforced polymer composites. Finally, complex components were prepared to verify the feasibility and versatility of the technique.Highlights A CCFRTCs mold‐less curing method was proposed. The effect of key parameters on the properties of CCFRTCs was clarified. Both the advantages of thermoset and thermoplastic materials were obtained. Complex components with low porosity were prepared.

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Section: Resultsmentioning

confidence: 99%

Section: Demonstration Of 3d Printed Ccfrtcsmentioning

confidence: 99%

Investigation on the mold‐less curing process of 3D printing continuous carbon fiber reinforced thermoset composites based on thermoplastic shells constraint

Zhao,

Wang,

Duan

et al. 2023

Polymer Composites

View full text Add to dashboard Cite

show abstract

“…CFR offers several compelling advantages, including the production of parts that are significantly stronger and lighter than those made from conventional materials, making it ideal for high-performance applications. The technology allows for complex geometries that are difficult to achieve with traditional composite manufacturing techniques, along with reduced waste and shorter production cycles [118]. Additionally, the ability to customize the fiber orientation provides unparalleled control over the mechanical properties of the final part.…”

Section: Advantages and Limitations Of Cfrmentioning

confidence: 99%

Additive Manufacturing: A Comprehensive Review

Zhou,

Miller,

Vezza

et al. 2024

Sensors

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Additive manufacturing has revolutionized manufacturing across a spectrum of industries by enabling the production of complex geometries with unparalleled customization and reduced waste. Beginning as a rapid prototyping tool, additive manufacturing has matured into a comprehensive manufacturing solution, embracing a wide range of materials, such as polymers, metals, ceramics, and composites. This paper delves into the workflow of additive manufacturing, encompassing design, modeling, slicing, printing, and post-processing. Various additive manufacturing technologies are explored, including material extrusion, VAT polymerization, material jetting, binder jetting, selective laser sintering, selective laser melting, direct metal laser sintering, electron beam melting, multi-jet fusion, direct energy deposition, carbon fiber reinforced, laminated object manufacturing, and more, discussing their principles, advantages, disadvantages, material compatibilities, applications, and developing trends. Additionally, the future of additive manufacturing is projected, highlighting potential advancements in 3D bioprinting, 3D food printing, large-scale 3D printing, 4D printing, and AI-based additive manufacturing. This comprehensive survey aims to underscore the transformative impact of additive manufacturing on global manufacturing, emphasizing ongoing challenges and the promising horizon of innovations that could further elevate its role in the manufacturing revolution.

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Eco‐friendly enhancement of mechanical properties in 3D carbon felt reinforced epoxy/aluminum sandwich composites via NaCl‐based anodizing and triton X‐100 modification

Taieh,

Fahad

2024

Polymer Composites

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To address the challenges of achieving strong adhesion between aluminum face sheets and composite cores (3D carbon felts) in sandwich structures, this work presents a novel approach that prioritizes safety, environmental sustainability, and ease of processing. The 3D CFs/Epoxy core was modified with Triton X‐100 in amounts from 0 to 10 wt% of the epoxy resin. The aluminum alloy face sheets were anodized at voltages from 0 to 11 V, using a NaCl‐based anodizing process. The technique of anodizing can enhance the bond between the aluminum face sheets and the 3D CFs/epoxy core, resulting in improved mechanical performance of the composite, including flexural and compressive testing, as well as dynamic mechanical analysis. The composite, embedding 3D CFs foam in epoxy resin, has a storage modulus 65.1% higher than pure epoxy at 2070 MPa. In addition, increasing Triton X‐100 content (1–10 wt%) decreases the storage modulus from 1886 to 1314 MPa and the glass transition temperature from 68.3 to 62.8 °C. Additionally, with Triton X‐100 concentrations of 1 to 10 wt%, the flexural modulus of the epoxy reinforced by 3D CFs drops from 3951.8 to 2400 MPa, and the flexural strength decreases by 55.3% from 174 to 112 MPa, indicating reduced structural rigidity. For sandwich composites with anodized aluminum face sheets, a 7 V anodizing voltage boosts the flexural modulus from 17.8 GPa (0 V) to 36.2 GPa. At 7 V, compressive strength and strain rise by 346.9% and 995.5%, respectively. Flexural toughness peaks at 11239 KJ/m3 with 5 wt% Triton X‐100.Highlights Developed new sandwich epoxy composites consisting of anodized aluminum sheet treated with NaCl and modified 3D carbon felts epoxy composites using Triton X‐100. Aluminum face sheets underwent an anodization at different voltages (0, 5, 7, 9, and 11 volts), aiming to enhance the bonding between the aluminum sheets and the 3D CFs/epoxy core. Triton X‐100 was utilized to modify the epoxy matrix at various concentrations (0 to 10 wt%) for improving the flexibility of the sandwich core. The sandwich composites incorporating the un‐anodized face sheet have shown flexural modulus of about 17.8 GPa. The modulus achieves its maximum value of 36.2 GPa when anodized at 7 V, indicating a 103% increase. The flexural strength of sandwich composites increases by 13% (272 MPa) when the Triton X‐100 concentration is raised to 5 wt%, compared to the 240 MPa flexural strength of the Al face sheet anodized at 7 V.

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A Mechanical Performance Study of Dual Cured Thermoset Resin Systems 3D-Printed with Continuous Carbon Fiber Reinforcement

Cited by 15 publications

References 45 publications

Investigation on the mold‐less curing process of 3D printing continuous carbon fiber reinforced thermoset composites based on thermoplastic shells constraint

Investigation on the mold‐less curing process of 3D printing continuous carbon fiber reinforced thermoset composites based on thermoplastic shells constraint

Additive Manufacturing: A Comprehensive Review

Eco‐friendly enhancement of mechanical properties in 3D carbon felt reinforced epoxy/aluminum sandwich composites via NaCl‐based anodizing and triton X‐100 modification

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