Dynamic Capillary-Driven Additive Manufacturing of Continuous Carbon Fiber Composite

Abstract

This composite 3D-printing technology is based on a capillary effect through thermal gradient applied onto carbon fibers to allow deposited liquid polymers to simultaneously flow and become solid so as to form 3D structures. We also developed a robotic system consisting of a uniquely designed printing head and an automated robot arm, yielding a 3D printer that enables us to print a thermosetting composite with arbitrary shape and complex geometry on 2D and 3D substrates or in free space without supporting structures.

A systematic review on high‐performance fiber‐reinforced 3D printed thermoset composites

“…On the other hand, the use of low volume fraction (i.e., 10 wt%) enables a complex component additive manufacturing (Figure 3 (C)), establishing the challenge of optimizing the AM process for high fiber content, suitable for structural applications. [36] Based on Shi et al, [12] Sanei et al [27] , and Van de Werken et al, [7,39] Figure 4 exhibits the mechanical property variation associated with the fiber size and the working temperature based on the glass transition temperature (T g ) of the matrix. As previously mentioned, the increase in fiber size increases the mechanical behavior; meanwhile, the working temperature is governed mainly by the matrix (thermoplastic or thermoset).…”

“…The thermoset matrices allow the material application at higher glass transition due to the strong molecular cross-link interaction compared with thermoplastic matrices used for AM. [12] The fiber size used also limits the AM method to be employed, in which the fused filament fabrication (FFF) and localized in-plane thermal assisted (LITA) present methods of impregnating long fibrous reinforcement. [12,32] On the other hand, direct ink writing (DIW) and stereolithography (SLA) processing are useful for short fibers.…”

“…[12] The fiber size used also limits the AM method to be employed, in which the fused filament fabrication (FFF) and localized in-plane thermal assisted (LITA) present methods of impregnating long fibrous reinforcement. [12,32] On the other hand, direct ink writing (DIW) and stereolithography (SLA) processing are useful for short fibers. [15,36] AM composites aim to achieve similar properties as those produced via conventional manufacturing processes with high fiber volume fraction and low defects.…”

“…[8][9][10][11] However, there is a considerable difficulty in controlling viscosity for deposition and curing the printed material, maintaining its complex threedimensional geometry-an essential factor for AM. [12,13] As a response, a significant number of studies have been developed aiming at improving the processability, such as the optimal set of printing speed/thickness, printing direction, thermoset matrix, and fiber used, AM type, among others. [14][15][16] Thermoset matrices application through AM relies on a new horizon in terms of efficiently processing parts and components with the advantages of possessing suitable mechanical properties while having complex geometries and little tooling.…”

Additive Manufacturing of Polymer Materials: Progress, Promise and Challenges

“…It also reduces warping and enables a larger build envelope [121]. Shi et al [122] reported a dynamic capillary-driven additive manufacturing approach for manufacturing of continuous carbon fiber composites. This approach offers control over viscosity and degree of curing of carbon fiber composites.…”