Mechanical Characterization of High-Temperature Carbon Fiber-Polyphenylene Sulfide Composites for Large Area Extrusion Deposition Additive Manufacturing

Yeole, Pritesh; Hassen, Ahmed Arabi; Kim, Seokpum; Lindahl, John; Kunc, Vlastimil; Franc, Alan; Vaidya, Uday

doi:10.1016/j.addma.2020.101255

Cited by 18 publications

(17 citation statements)

References 28 publications

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“…As will be shown in Section 4, many new experimental systems for both small- and large-scale applications appeared in the period from 2014 to 2018 [ 15 – 29 , 32 , 34 , 35 , 37 ], which can be related to the high number of publications in the same period. Although the scientific production in the last 2 years decreased, a crescent share of the research was carried out with commercial systems [ 48 , 49 , 51 , 53 , 54 , 65 – 69 , 71 – 73 , 75 ], indicating the consolidation of screw-assisted EAM in the market.…”

Section: Search Resultsmentioning

confidence: 99%

“…The USA respond for most publications (16), followed by the UK (14), and India (8). The authors from the USA account for most publications using large-scale AM systems [ 63 – 69 ] and recycling AM [ 70 – 73 ]. With relation to the UK, most research was conducted on additive bio-manufacturing (bio-AM) [ 19 – 23 , 45 – 49 ], defined by Ferrari et al [ 77 ] as the “ use of 3D printing for medical purposes or non-therapeutic ‘human enhancement’, whether they involve the production of biological material or not.…”

Section: Search Resultsmentioning

confidence: 99%

“…Process feasibility was first demonstrated using neat polymer pellets but, due to the expressive distortion and warping, fiber-reinforced materials became preferred. The BAAM® machine was explored in several publications, using diverse materials, including composites based on high-temperature thermoplastics [ 65 , 67 – 69 ]. Due to the significant difference between the large- and small-scale EAM, the BAAM® process was investigated with the aid of thermomechanical modeling [ 64 ], leading to the development of specific design guidelines for large-scale 3D printing by Roschli et al [ 66 ].…”

Section: Technological Evolution Of Screw-assisted Eammentioning

confidence: 99%

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Screw-assisted 3D printing with granulated materials: a systematic review

Netto

Idogava

Santos

et al. 2021

Int J Adv Manuf Technol

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This paper presents a systematic review on extrusion additive manufacturing (EAM), with focus on the technological development of screw-assisted systems that can be fed directly with granulated materials. Screw-assisted EAM has gained importance as an enabling technology to expand the range of 3D printing materials, reduce costs associated with feedstock fabrication, and increase the material deposition rate compared to traditional fused filament fabrication (FFF). Many experimental printheads and commercial systems that use some screw-processing mechanism can be found in the literature, but the design diversity and lack of standard terminology make it difficult to determine the most suitable solutions for a given material or application field. Besides, the few previous reviews have offered only a glimpse into the topic, without an in-depth analysis about the design of the extruders and associated capabilities. A systematic procedure was devised to identify the screw-assisted EAM systems that can print directly from granulated materials, resulting in 61 articles describing different pieces of equipment that were categorized as experimental printheads and commercial systems, for small- and large-scale applications. After describing their main characteristics, the most significant extruder modifications were discussed with reference to the materials processed and performance requirements. In the end, a general workflow for the development of 3D printers based on screw extrusion was proposed. This review intends to provide information about the state-of-the-art screw-assisted EAM and help the academy to identify further research opportunities in the field.

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Section: Search Resultsmentioning

confidence: 99%

Section: Search Resultsmentioning

confidence: 99%

Section: Technological Evolution Of Screw-assisted Eammentioning

confidence: 99%

See 1 more Smart Citation

Screw-assisted 3D printing with granulated materials: a systematic review

Netto

Idogava

Santos

et al. 2021

Int J Adv Manuf Technol

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“…It can be observed from Figure 3B, the crack was initiated at the intersection; however, propagated through the AM section due to weak Z‐strength (layer‐to‐layer bonding) in the AM substrate. [ 16 ] It can be concluded from Figure 3A that the BMI resin did not flow inside the groove between the beads. Therefore, further means for improvement of the bond strength between the AM substrate and the CF‐BMI skin was needed.…”

Section: Resultsmentioning

confidence: 99%

“…composite lay‐up area) was less than 0.1 mm for both tools. There are two drawbacks to this approach as, the subtractive process leads to material waste, and Additive Manufacturing (AM) components possess inter‐layer and intra‐layer porosity, [ 16 ] which result in the possibility of exposing voids during machining; (b) the alternative approach is to manufacture the mold slightly undersized and add layer(s) of coating to achieve the desired mold geometry. This research is focused on the second approach.…”

Section: Introductionmentioning

confidence: 99%

Improve durability and surface quality of additively manufactured molds using carbon fiber prepreg

et al. 2021

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Hybrid tooling is an emerging concept introduced in the aerospace industries to reduce weight and cost of traditional tools. A hybrid tool features a skin, which provides desired surface quality, durability, and a low-density substrate to reduce the weight of the mold. The big area additive manufacturing (BAAM) technology permits rapid production of thermoplastic polymer intensive large-scale structures. The present study features a carbon fiber reinforced polyphenylene sulfide (CF-PPS) substrate fabricated using Oak Ridge National Laboratory's BAAM system. Carbon fiber-bismaleimide (CF-BMI) prepreg skin was then bonded to the BAAM tool through high-pressure autoclave molding. Process optimization was conducted to improve the bonding between CF-PPS and CF-BMI (transverse tensile strength increased from 0.54 to 4.8 MPa). Durability of the mold was demonstrated from fabricating seven (7) carbon fiber-Huntsman epoxy hand lay-up parts utilizing the mold.

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Additive Manufacturing of Poly(phenylene Sulfide) Aerogels via Simultaneous Material Extrusion and Thermally Induced Phase Separation

Godshall,

Rau,

Williams

et al. 2023

Advanced Materials

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Additive manufacturing (AM) of aerogels increases the achievable geometric complexity, and affords fabrication of hierarchically porous structures. In this work, a custom heated material extrusion (MEX) device prints aerogels of poly(phenylene sulfide) (PPS), an engineering thermoplastic, via in situ thermally induced phase separation (TIPS). First, pre‐prepared solid gel inks are dissolved at high temperatures in the heated extruder barrel to form a homogeneous polymer solution. Solutions are then extruded onto a room‐temperature substrate, where printed roads maintain their bead shape and rapidly solidify via TIPS, thus enabling layer‐wise MEX AM. Printed gels are converted to aerogels via postprocessing solvent exchange and freeze‐drying. This work explores the effect of ink composition on printed aerogel morphology and thermomechanical properties. Scanning electron microscopy micrographs reveal complex hierarchical microstructures that are compositionally dependent. Printed aerogels demonstrate tailorable porosities (50.0–74.8%) and densities (0.345–0.684 g cm−3), which align well with cast aerogel analogs. Differential scanning calorimetry thermograms indicate printed aerogels are highly crystalline (≈43%), suggesting that printing does not inhibit the solidification process occurring during TIPS (polymer crystallization). Uniaxial compression testing reveals that compositionally dependent microstructure governs aerogel mechanical behavior, with compressive moduli ranging from 33.0 to 106.5 MPa.

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Mechanical Characterization of High-Temperature Carbon Fiber-Polyphenylene Sulfide Composites for Large Area Extrusion Deposition Additive Manufacturing

Cited by 18 publications

References 28 publications

Screw-assisted 3D printing with granulated materials: a systematic review

Screw-assisted 3D printing with granulated materials: a systematic review

Improve durability and surface quality of additively manufactured molds using carbon fiber prepreg

Additive Manufacturing of Poly(phenylene Sulfide) Aerogels via Simultaneous Material Extrusion and Thermally Induced Phase Separation

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