TY - GEN
T1 - Challenges in Additively Manufactured Thermoset Continuously Reinforced Composites
AU - Furmanski, Jevan
AU - Abbott, Andrew
AU - Tandon, G. P.
AU - Flores, Mark
AU - Barnett, Philip
AU - Salviato, Marco
AU - Baur, Jeffery
AU - Butcher, Dennis
N1 - The authors would like to thank Nathan Stranberg and Max Johnson of Continuous Composites, Inc. for manufacturing of components and discussions on the CF3D process. The authors would also like to thank James Joo of AFRL/RQVS for the use of their TO wing sub-structure design.
PY - 2022
Y1 - 2022
N2 - Continuously-reinforced composite additive manufacturing (CC-AM) is set to revolutionize the manufacturing and design of high-strength, low-weight structures. Longitudinal tensile strengths of CC-AM have been reported exceeding 1500 MPa with minimal porosity, making this system a candidate for scale-up and structural applications. However, there remain a number of morphological non-idealities that are unique to the CC-AM process that limit the performance of a complex AM build. These can be categorized into material non-idealities (fiber clustering, resin-rich zones, matrix quality) and topological constraint non-idealities (joint design constraints, minimum path radius, tow cuts). Furthermore, for UV snap-cured carbon fiber CC-AM, limited penetration of the UV radiation through the carbon fiber tow presents a challenge to achieving optimal in-situ curing. The present work lays out these challenges both in a general sense, with specific case examples for material built with the CF3D system (Continuous Composites Inc.) using T-1100 12K carbon fiber tows and a UV snap curing acrylate resin. Most of the issues highlighted are inherent to CC-AM, and so most of the recommendations for future development to mitigate the various non-idealities are expected to translate to other CC-AM technologies, such as those employing a thermoplastic polymer matrix.
AB - Continuously-reinforced composite additive manufacturing (CC-AM) is set to revolutionize the manufacturing and design of high-strength, low-weight structures. Longitudinal tensile strengths of CC-AM have been reported exceeding 1500 MPa with minimal porosity, making this system a candidate for scale-up and structural applications. However, there remain a number of morphological non-idealities that are unique to the CC-AM process that limit the performance of a complex AM build. These can be categorized into material non-idealities (fiber clustering, resin-rich zones, matrix quality) and topological constraint non-idealities (joint design constraints, minimum path radius, tow cuts). Furthermore, for UV snap-cured carbon fiber CC-AM, limited penetration of the UV radiation through the carbon fiber tow presents a challenge to achieving optimal in-situ curing. The present work lays out these challenges both in a general sense, with specific case examples for material built with the CF3D system (Continuous Composites Inc.) using T-1100 12K carbon fiber tows and a UV snap curing acrylate resin. Most of the issues highlighted are inherent to CC-AM, and so most of the recommendations for future development to mitigate the various non-idealities are expected to translate to other CC-AM technologies, such as those employing a thermoplastic polymer matrix.
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M3 - Conference contribution
AN - SCOPUS:85139548774
T3 - Proceedings of the American Society for Composites - 37th Technical Conference, ASC 2022
BT - Proceedings of the American Society for Composites - 37th Technical Conference, ASC 2022
A2 - Zhupanska, Olesya
A2 - Madenci, Erdogan
PB - DEStech Publications Inc.
T2 - 37th Technical Conference of the American Society for Composites, ASC 2022
Y2 - 19 September 2022 through 21 September 2022
ER -