Title: Hybrid Technology Development to Directly Print Thermoset Molds for Composites

Authors: Shai Hirsch, Guido Klingiel, Ido De-La-Vega, Moav Winnykamien

DOI: 10.33599/nasampe/c.22.0003

Abstract: The manufacturing and assembly of composite components requires various kinds of tools, which determine their accuracy, performance and cost. Additive manufacturing (AM), also known as 3D printing technology has a direct impact on manufacturing the composite structures by offering rapid molds production. 3D printing of molds, jigs and fixtures for composites manufacturing expands flexibility and design opportunities, and reduces costs and lead-time. Large-format AM systems, that can create an object larger than 1 m3, are the only systems that fit rapid mold production. Most of these systems are based on single-screw thermoplastic pellet extruder. Massivit 3D developed a novel technology, named Cast In Motion (CIM), and a designated system, Massivit 10000, for direct digital printing of tools and molds, made of a proprietary developed epoxy, CIM 500. This technology consists of printing a double wall shell made of a proprietary UV cured Water Breakable (WB) material, Dimengel, followed by casting a calculated amount of CIM 500. The WB printing and the epoxy casting processes operate intermittently to create a near net shape epoxy mold encapsulated by WB shell. After the encapsulated mold is post-cured, it is immersed in a water bath and / or machined for the WB shell removal, in order to obtain the desired mold geometry. The Massivit 10000 system can also be used for printing of geometric cores and soluble mandrels for the composites industry by utilizing the printing of the WB and other various acrylic base UV cured materials without the conjunction of the CIM 500. This paper presents the advancements in the CIM technology with its proprietary materials to enable direct manufacturing of complex finished molds. It also presents various applications from the design phase through experiments that introduce meeting the customers` requirements. Keywords: Large-format Additive Manufacturing, 3D printing, Thermoset, Mold, Composites

References: [1] Rajkumar Velu, Nahaad Vaheed, and Felix Raspall, Design and Robotic Fabrication of 3d Printed Moulds For Composites, Solid Freeform Fabrication 2018: Proceedings of the 29th Annual International [2] Vlastimil Kunc, Ahmed Arabi Hassen, John Lindahl, Seokpum Kim, Brian Post, Lonnie Love, Large Scale Additively Manufactured Tooling For Composites, 15th Japan International Sampe Symposium and Exhibition, 2018

Conference: CAMX 2022

Publication Date: 2022/10/17

SKU: TP22-0000000003

Pages: 16

Price: $32.00