Title: FREEFORM PRINTING OF THERMALLY CURABLE THERMOSET COMPOSITES

Authors: Mostafa Yourdkhani, Carter Dojan, Morteza Ziaee

DOI: 10.33599/nasampe/s.23.0266

Abstract: Conventional manufacture of fiber-reinforced polymer composites relies on heating and curing the matrix thermoset resin at elevated temperatures for several hours using large autoclaves or ovens. Additionally, expensive molds or tooling are typically required to shape the constituents. In marked contrast, additive manufacturing (AM) allows flexible design and rapid, energy-efficient fabrication of composite parts with minimal tooling at a lower cost and higher design flexibility. However, integration of traditional resins with long cure cycles in AM processes is quite challenging or even impossible. We have developed a novel AM technique that can realize fast and energy-efficient fabrication of high-performance thermoset composites with minimal tooling. In our approach, we develop cure-on-demand resins that can be instantaneously cured and rigidized by a local thermal stimulus. Use of a robotic platform to feed the uncured material followed by instantaneous curing enables fast, unprecedented printing of high-quality continuous- or discontinuous carbon fiber composites in mid-air without using support materials. This novel technique is of great interest to various industries such as aerospace, automotive, and energy sectors due to its potential for reducing composite manufacturing cost and time.

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Conference: SAMPE 2023

Publication Date: 2023/04/17

SKU: TP23-0000000266

Pages: 8

Price: $16.00