Structural stability of thin overhanging walls during material extrusion additive manufacturing of thermoset-based ink

Romberg, Stian K.; Abir, Abrian I.; Hershey, Christopher; Kunc, Vlastimil; Compton, Brett G.

doi:10.1016/j.addma.2022.102677

Cited by 10 publications

(9 citation statements)

References 35 publications

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“…This is of particular interest when considering the application space of such a structure. To accomplish this feat using conventional DIW manufacturing, the thin‐walled structure would likely need to be printed with support material, [ 32 ] then removed from the original print substrate and repositioned in an inverted configuration, thereby compromising the bond strength between the structure and end‐use surface. Conversely, the proposed unstructured print technique can satisfy this load‐bearing task with an as‐printed, high‐strength structure.…”

Section: Resultsmentioning

confidence: 99%

“…This can be attributed to the sensitivity to gravitational effects on the viscoelastic, shear‐thinning DIW inks requiring the extrusion nozzle to be facing downward during deposition, at the cost of impeding formable geometries. [ 32 ] To overcome this barrier, a rapidly solidifying DIW ink must be utilized. To achieve this, researchers have investigated inks with polymer networks catalyzed via continuous ultraviolet (UV) irradiation.…”

Section: Introductionmentioning

confidence: 99%

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Unstructured Direct Ink Write 3D Printing of Functional Structures with Ambient Temperature Curing Dual‐Network Thermoset Ink

Armstrong

Liang

Demoly

et al. 2022

Advanced Intelligent Systems

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Fabrication of structures in unstructured environments is a promising field to expand the application spaces of additive manufacturing (AM). One potential application is to add new components directly onto existing structures. Herein, a versatile, reconfigurable direct ink writing (DIW) manufacturing method is developed in tandem with a two‐stage hybrid ink designed to fabricate high‐strength, self‐supporting parts in unconventional printing spaces such as underneath a build surface or horizontally. This two‐stage hybrid DIW ink combines a photopolymer and a tough epoxy resin. The photopolymer can cure rapidly to enable layer‐by‐layer printing of complex structures. It also possesses adequate adhesion to allow the fabrication of large volume structures on a diversity of substrates including acrylic, wood, glass, aluminum, and concrete. The epoxy component can cure after 72 h in ambient conditions with further increased adhesion strengths. The capabilities of the reconfigurable DIW extrusion nozzle method to print complex structures in inverted and horizontal environments are demonstrated. Finally, via addition of DIW‐deposited conductive paths, a functional 3D‐printed structure capable of in situ deformation monitoring is created. This work has the potential to be used for applications such as appending new parts to existing structures for increasing functionality, repair, and structure health monitoring.

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Unstructured Direct Ink Write 3D Printing of Functional Structures with Ambient Temperature Curing Dual‐Network Thermoset Ink

Armstrong

Liang

Demoly

et al. 2022

Advanced Intelligent Systems

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“…The SMP-10-Z ink is similar in composition to the ZrB 2 and SMP-10 formulation described in Kemp et al, 5 with the only difference being that, in the present study, the ZrB 2 was not ball milled. FA was selected over a different rheology modifier (like fumed silica) or other commonly used nano-particle materials (like nano-SiC) used in material extrusion AM inks 23,24 for two primary reasons: (1) because pure alumina has a higher melting temperature (2 072 • C) than pure silica (1 710 • C), and (2) the hydrophobized Aeroxide Alu C 805 was found to be an effective rheology modifier for SMP-10 resin compared to other fumed alumina (FA) products that were either hydrophilic or had different surface functionalization. While nano-SiC would be an excellent candidate for the composite after printing and pyrolysis, it is unlikely (though, admittedly, unproven) to impart desirable printing properties to the ink in the same way that a fumed silica or FA would.…”

Section: Materials and Mixingmentioning

confidence: 99%

Size effects in 3D‐printed polymer‐derived, zirconium diboride‐reinforced ceramic composites

Kemp,

Reed,

Compton

2023

J Am Ceram Soc.

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Preceramic polymers are of interest for use in many manufacturing techniques such as injection molding, ceramic fiber infiltration, and additive manufacturing. However, off‐gassing of low molecular weight oligomers occurs when these polymers cure, potentially leading to porosity in the cured part. To study how porosity and strength are affected by the size of the printed part, and the presence of a high surface area nano‐scale filler, polycarbosilane (PCS) microrods of varying diameter were fabricated via direct ink writing (DIW), an additive manufacturing technique, with two ink formulations containing either zirconium diboride (ZrB2) alone, or ZrB2 and fumed alumina (FA). Sets of microrods were printed in a range of sizes by using print nozzles of 450, 634, 979, 1 346, or 1 702 μm in diameter, which were thermally cured, pyrolyzed to form ceramic composite microrods, and tested in 3‐pt flexure. Porosity increased with increasing diameter, while failure strength decreased. For a given nozzle size, the microrods containing FA displayed lower porosity and higher strength (up to ∼500 MPa) compared to the microrods containing only ZrB2. Weibull strength analysis was performed on each group of microrods and shows that the addition of FA increased Weibull modulus from 4.63 ± 1.56 to 9.35 ± 0.601. In conjunction with optical microscopy, this analysis indicates two distinct flaw populations in the printed materials, porosity which arises during the curing step and cracking which arises during pyrolysis of the larger specimens.

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“…However, these samples were never machined nor tested. At the time of this report, several thermoset material systems have been printed and their rheological and mechanical properties tested through other research projects [29][30][31][32][33][34][35][36].…”

Section: Initial Thermoset Printing Of Test Samplesmentioning

confidence: 99%

Relevant Additive Manufacturing Materials for Wind Industry

Kishore

Smith

Kim

et al. 2022

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Structural stability of thin overhanging walls during material extrusion additive manufacturing of thermoset-based ink

Cited by 10 publications

References 35 publications

Unstructured Direct Ink Write 3D Printing of Functional Structures with Ambient Temperature Curing Dual‐Network Thermoset Ink

Unstructured Direct Ink Write 3D Printing of Functional Structures with Ambient Temperature Curing Dual‐Network Thermoset Ink

Size effects in 3D‐printed polymer‐derived, zirconium diboride‐reinforced ceramic composites

Relevant Additive Manufacturing Materials for Wind Industry

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