Three-dimensional printing of continuous-fiber composites by in-nozzle impregnation

Matsuzaki, Ryosuke; Ueda, Masahiro; Namiki, Masaki; Jeong, Tae Kun; Asahara, Hirosuke; Horiguchi, Keisuke; Nakamura, Takanobu; Todoroki, Akira; Hirano, Yoshiyasu

doi:10.1038/srep23058

Cited by 896 publications

(519 citation statements)

References 39 publications

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“…Recently, it has been demonstrated that 3D printing technology can be used to produce materials with finely tuned structural properties [31,32]. In the near future it may also become possible to realize experimentally the limit of high disorder studied here.…”

Section: Localized Load Sharingmentioning

confidence: 98%

Fractal frontiers of bursts and cracks in a fiber bundle model of creep rupture

2015

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Abstract.We investigate the eect of the amount of disorder on the fracture process of heterogeneous materials in the framework of a fiber bundle model. The limit of high disorder is realized by introducing a power law distribution of fiber strength over an infinite range. We show that on decreasing the amount of disorder by controlling the exponent of the power law the system undergoes a transition from the quasi-brittle phase where fracture proceeds in bursts to the phase of perfectly brittle failure where the first fiber breaking triggers a catastrophic collapse. For equal load sharing in the quasi-brittle phase the fat tailed disorder distribution gives rise to a homogeneous fracture process where the sequence of breaking bursts does not show any acceleration as the load increases quasi-statically. The size of bursts is power law distributed with an exponent smaller than the usual mean field exponent of fiber bundles. We demonstrate by means of analytical and numerical calculations that the quasi-brittle to brittle transition is analogous to continuous phase transitions and determine the corresponding critical exponents. When the load sharing is localized to nearest neighbor intact fibers the overall characteristics of the failure process prove to be the same, however, with dierent critical exponents. We show that in the limit of the highest disorder considered the spatial structure of damage is identical with site percolation-however, approaching the critical point of perfect brittleness spatial correlations play an increasing role, which results in a dierent cluster structure of failed elements.

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Section: Localized Load Sharingmentioning

confidence: 98%

Fractal frontiers of bursts and cracks in a fiber bundle model of creep rupture

2015

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“…This trend could be further supported by adopting new far more diverse polymer recycling codes to further expand the materials selection while reducing costs [94]. In addition, there is a large potential for research into new composite filaments with TPE as the matrix and carbon or steel fiber as reinforcement [105][106][107][108][109]. This could open new possibilities for 3-D printing belts that do not stretch and deform (while enabling the RepRap community one step closer to complete self-replication).…”

Section: Likelihood Of a Consumer Buying A 3-d Printer For Savingsmentioning

confidence: 99%

Distributed Manufacturing of Flexible Products: Technical Feasibility and Economic Viability

Woern

Pearce

2017

Technologies

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Abstract:Distributed manufacturing even at the household level is now well established with the combined use of open source designs and self-replicating rapid prototyper (RepRap) 3-D printers. Previous work has shown substantial economic consumer benefits for producing their own polymer products. Now flexible filaments are available at roughly 3-times the cost of more conventional 3-D printing materials. To provide some insight into the potential for flexible filament to be both technically feasible and economically viable for distributed digital manufacturing at the consumer level this study investigates 20 common flexible household products. The 3-D printed products were quantified by print time, electrical energy use and filament consumption by mass to determine the cost to fabricate with a commercial RepRap 3-D printer. Printed parts were inspected and when necessary tested for their targeted application to ensure technical feasibility. Then, the experimentally measured cost to DIY manufacturers was compared to low and high market prices for comparable commercially available products. In addition, the mark-up and potential for long-term price declines was estimated for flexible filaments by converting thermoplastic elastomer (TPE) pellets into filament and reground TPE from a local recycling center into filament using an open source recyclebot. This study found that commercial flexible filament is economically as well as technically feasible for providing a means of distributed home-scale manufacturing of flexible products. The results found a 75% savings when compared to the least expensive commercially equivalent products and 92% when compared to high market priced products. Roughly, 160 flexible objects must be substituted to recover the capital costs to print flexible materials. However, as previous work has shown the Lulzbot Mini 3-D printer used in this study would provide more than a 100% ROI printing one object a week from hard thermoplastics, the upgrade needed to provide flexible filament capabilities can be accomplished with 37 average substitution flexible prints. This, again easily provides a triple digit return on investment printing one product a week. Although these savings, which are created by printing objects at home are substantial, the results also have shown the savings could be further increased to 93% when the use of a pellet extruder and TPE pellets, and 99% if recycled TPE filament made with a recyclebot is used. The capital costs of a recyclebot can be recovered in the manufacturing of about 9 kg of TPE filament, which can be accomplished in less than a week, enabling improved environmental impact as well as a strong financial return for heavy 3-D printer users.

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“…Due to this reason they are used very often as safety shields for engine cowls. Lot of research work is being carried out on additive manufacturing of composites reinforced with aramid fibre for their application in aerospace engineering [53].…”

Section: Glass Fiber Reinforced Compositesmentioning

confidence: 99%

A Review on Properties of Aerospace Materials Through Additive Manufacturing

2017

IJMTER

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Abstract-Additive Manufacturing (AM) process has been effective in producing materials that are being utilized by the aerospace industry in order to improve their performance by increasing their properties. Industry now opts for this technique over conventional methods as it has enormous advantages and applications. This Additive Manufacturing process is capable of producing complex near net shape of parts. The materials that are produced by this technique for aerospace industries are metal alloys, metal matrix composites, polymer matrix composites, ceramic matrix composites and nano-composites. Many of the composite materials are still under research and development. In this study, a literature review on the mechanical properties of the materials that are used in the aerospace industry by AM process is discussed and these properties are also compared with the materials produced by conventional methods. The purpose of this review is to highlight the importance of Additive Manufacturing technique and also understand the effect of this process on the materials tested. During this work, the evolution of materials in the aerospace sector, the basic concept of AM technique, the application of the materials, the properties obtained when processing is done, the limitations and the scope for research are given.

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Three-dimensional printing of continuous-fiber composites by in-nozzle impregnation

Cited by 896 publications

References 39 publications

Fractal frontiers of bursts and cracks in a fiber bundle model of creep rupture

Fractal frontiers of bursts and cracks in a fiber bundle model of creep rupture

Distributed Manufacturing of Flexible Products: Technical Feasibility and Economic Viability

A Review on Properties of Aerospace Materials Through Additive Manufacturing

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