Title: Additive Manufacturing of Three-Dimensional Carbon Fiber Scaffold from Recycled Carbon Fibers

Authors: Chunyan Zhang, Kaiyue Deng, Annie Porter, Chaoying Ni, Kun (Kelvin) Fu

DOI: 10.33599/nasampe/s.22.0827

Abstract: Carbon-based (e.g., carbon fiber or carbon nanotube) materials, due to the superb mechanical, biological properties and good chemical stability, are promising structural materials for applications in biotechnology, energy, aerospace and automotive. However, these materials are facing obstacles in developing net-shape manufacturing and processing into intricate geometries. Here, we report a strategy to produce composites through additive manufacturing of three-dimensional carbon scaffold using recycled carbon fibers (rCFs). The 3D carbon scaffold structure is enabled by a shear flow of rCFs in a thermoplastic matrix, followed by debinding and sintering to achieve well-bonded, oriented rCF scaffold. This rCF scaffold offers complex geometry design flexibility and multiscale reinforcing effect for 3D composite structures. Our processing strategy provides a rapid processing route, which increases cost-efficiency and structure scalability of structural carbon fiber composite production by infiltrating thermoset resin into the scaffold, and a solution to the recycling and reutilization of carbon fiber wastes.

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Conference: SAMPE 2022

Publication Date: 2022/05/23

SKU: TP22-0000000827

Pages: 11

Price: $22.00