Title: Continuous Fiber 3D printing for Compression OverMolding

Authors: Tyler Smith, James Brackett, Roo Walker, Vipin Kumar, David Nuttall, Ryan Ogle, Julian Charron, Chad Duty, Vlastimil Kunc, Ahmed Arabi Hassen

DOI: 10.33599/nasampe/c.23.0197

Abstract: Additive manufacturing systems can be used to create parts with unique anisotropic properties due to fiber alignment along the deposition direction. An Additive Manufacturing Compression Molding system was developed at Oak Ridge National laboratory to combine the benefits of Additive Manufacturing and Compression Molding. Preforms are created using the additive extruder then compression molded to create parts from compression molding with optimized fiber alignment along the component. This technology is capable of creating parts within a three minute cycle time to ensure the fast rate process requirements of industry are meet. To further increase the mechanical performance of these components, continuous fiber can be printed on top of the mold prior to manufacturing the preform. This process can also be done by pre-printing the continuous fiber separately and placing along the mold to over mold the fiber into the structure. During the compression molding process, the two materials are fused together to create built in stiffeners along the loading direction. These modifications will enable the capability to custom place continuous carbon fiber inside the mold with bend radius that is currently not achievable through traditional means. Introduction of these fibers has demonstrated the ability to increase flexural strength by 57% and Flexural modulus by 49%. In addition, these fibers can be used to increase the strength between several parts by over molding continuous fiber along the joint.

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Conference: CAMX 2023

Publication Date: 2023/10/30

SKU: TP23-0000000197

Pages: 12

Price: $24.00