Additive Manufacturing Processing of Plastics for Mass Production of Composites Tooling: Technical and Economic Analysis

Cicala, Gianluca; Tosto, Claudio; Recca, Giuseppe; Patti, Antonella

doi:10.1002/masy.202000256

Cited by 3 publications

(3 citation statements)

References 13 publications

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“…Among these cutting-edge technologies, Liquid Crystal Display (LCD) printing has garnered considerable attention due to its simplicity, cost effectiveness, and ability to achieve high-resolution prints [1][2][3]. As a result, it has found widespread applications in diverse fields, including dentistry, microfluidic, jewelry design, toy manufacturing, and even composite tooling [4][5][6][7][8][9]. The core principle behind LCD printing involves the use of photosensitive resins that solidify when exposed to light, daylight, or UV light [10].…”

Section: Introductionmentioning

confidence: 99%

Epoxy-Based Blend Formulation for Dual Curing in Liquid Crystal Display 3D Printing: A Study on Thermomechanical Properties Variation for Enhanced Printability

Tosto,

Saitta,

Latteri

et al. 2024

Polymers

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The aim of this study was to explore the thermal properties of epoxy–acrylate blends for the liquid crystal display (LCD) 3D printing technique. Starting from an epoxy–acrylate blend with a ratio of epoxy to acrylate of 50:50, the effect of adding a reactive monofunctional epoxy diluent was evaluated. The diluent was a resin composed by oxirane, mono[(C12-14 alkyl) methyl] derivatives selected for its low viscosity (i.e., 1.8 Poise) at room temperature and its reactivity. The diluent content varied from 15 to 25 wt% and, for all the formulation, double curing cycles, where thermal curing followed photocuring, were studied. The effect of different curing temperatures was also evaluated. The control of the diluent content and of the curing temperature allowed tailoring of the thermomechanical resin properties while improving the resin’s processability. The glass transition ranged from 115.4 °C to 90.8 °C depending on the combination of diluent content and post-curing temperature. The resin developed displayed a faster processing time tested on a reference part with printing time of 4 h and 20 min that was much lower than the printing times (7 and 16 h) observed for the starting formulations.

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Section: Introductionmentioning

confidence: 99%

Epoxy-Based Blend Formulation for Dual Curing in Liquid Crystal Display 3D Printing: A Study on Thermomechanical Properties Variation for Enhanced Printability

Tosto,

Saitta,

Latteri

et al. 2024

Polymers

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“…Recently, several applications as lay-up tooling exploiting the synergy between fused deposition modeling (FDM) and FRP have been reported, since this AM process allows for not high manufacturing costs and lead times reduction, but still holding quality and repeatability features. [5][6][7] Moreover, the use of AM can be exploited for producing removable (such as soluble) tool, which is a perfect solution to fabricate hollow composite parts, [8,9] even having embed device within the composite structures itself. [10] Regarding lower-limb prosthesis, the use of sensing systems for interfacial residual limb-prosthesis' socket measurements is commonly used, since this kind of monitoring strategies, for example, for distribution of pressure and shear stresses measuring, permits to improve the quality of life and the comfort for patients, [11] by reducing the pain.…”

Section: Introductionmentioning

confidence: 99%

Design and Fabrication of a Customized and Fully‐Recyclable Carbon Fibers/Epoxy Composites Prostheses via a Functional Additive Manufacturing Approach

Saitta,

Tosto,

Pergolizzi

et al. 2023

Macromolecular Symposia

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This study presents an innovative approach based on the combination of two different techniques for fiber‐reinforced epoxy composites manufacturing, i.e., additive manufacturing (AM) and hand lay‐up‐assisted vacuum bagging. It represents a proof of concepts for the manufacturing of a customized and lightweight lower‐limb prostheses having built‐in functional elements, such as sensors. In particular, a soluble tool for fabricating a complex‐shaped carbon reinforced epoxy composite is produced by AM. The 3D printed model is properly designed to integrate a functional element, in a customized way, within the composite structure itself. Moreover, a fully‐recyclable epoxy resin system is used as matrix for the fabricated composite part to recover the expensive functional part and carbon fibers as soon as the prostheses has reached the end of its life (EoL). The prostheses recycle is carried out through a chemical recycling process that relies on the presence of acid‐cleavable groups within the epoxy‐cured network that allows for the cleavage of the crosslink under certain conditions. A similar approach is proposed in the state of art, but by using the traditional autoclave prepreg process and without considering the handling of the part at its EoL.

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“…Our research continued with the study of a new AM technology called liquid crystal display (LCD) printing. [ 4 ] This method employs daylight resins that crosslink when exposed to a specific wavelength (460 nm). The first advantage is that LCD printing develops a full layer at once, without the usage of print heads, by simply irradiating more dots in the same amount of time.…”

Section: Introductionmentioning

confidence: 99%

Comparison of Three Additive Manufacturing (AM) Techniques for Manufacturing Complex Hollow Composite Parts

Tosto

Pergolizzi

Cicala

2022

Macromolecular Symposia

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Additive manufacturing (AM) is well known for supporting the manufacturing of composites through the 3D printing of lay‐up tools, sacrificial mandrels, trim molds, etc. The fused deposition modeling (FDM) is a pioneer in composite tooling. This technique is advantageous in many scenarios in which it is convenient to obtain hollow composite parts by dissolving sacrificial mandrels, removing the use of expensive and heavy metal molds. However, the effects that the removal process has on the thermomechanical properties of the composite must be considered. The convenience of another AM technique, liquid crystal display (LCD) printing, has also recently been demonstrated. The present work aims to compare three different techniques, FDM, fused filament fabrication (FFF), and LCD, each using different materials and, therefore, different mandrel removal processes. DMA analyses have highlighted the impact of some dissolution processes on thermomechanical properties. Further mechanical analysis is conducted to support what is found in the thermomechanical characterization tests. Finally, an economic analyses highlight the time and cost savings of some AM technologies compared to the conventional method for manufacturing composite parts.

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Additive Manufacturing Processing of Plastics for Mass Production of Composites Tooling: Technical and Economic Analysis

Cited by 3 publications

References 13 publications

Epoxy-Based Blend Formulation for Dual Curing in Liquid Crystal Display 3D Printing: A Study on Thermomechanical Properties Variation for Enhanced Printability

Epoxy-Based Blend Formulation for Dual Curing in Liquid Crystal Display 3D Printing: A Study on Thermomechanical Properties Variation for Enhanced Printability

Design and Fabrication of a Customized and Fully‐Recyclable Carbon Fibers/Epoxy Composites Prostheses via a Functional Additive Manufacturing Approach

Comparison of Three Additive Manufacturing (AM) Techniques for Manufacturing Complex Hollow Composite Parts

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