UV-Assisted 3D Printing of Glass and Carbon Fiber-Reinforced Dual-Cure Polymer Composites

Abstract

Glass (GFR) and carbon fiber-reinforced (CFR) dual-cure polymer composites fabricated by UV-assisted three-dimensional (UV-3D) printing are presented. The resin material combines an acrylic-based photocurable resin with a low temperature (140 °C) thermally-curable resin system based on bisphenol A diglycidyl ether as base component, an aliphatic anhydride (hexahydro-4-methylphthalic anhydride) as hardener and (2,4,6,-tris(dimethylaminomethyl)phenol) as catalyst. A thorough rheological characterization of these formulations allowed us to define their 3D printability window. UV-3D printed macrostructures were successfully demonstrated, giving a clear indication of their potential use in real-life structural applications. Differential scanning calorimetry and dynamic mechanical analysis highlighted the good thermal stability and mechanical properties of the printed parts. In addition, uniaxial tensile tests were used to assess the fiber reinforcing effect on the UV-3D printed objects. Finally, an initial study was conducted on the use of a sizing treatment on carbon fibers to improve the fiber/matrix interfacial adhesion, giving preliminary indications on the potential of this approach to improve the mechanical properties of the 3D printed CFR components.

Acrylate‐based photosensitive resin for stereolithographic three‐dimensional printing

“…The viscosity is one of the most important parameters indicating the fluidity and printability of photosensitive resin combinations . Generally speaking, a low viscosity is required for SLA printing to achieve a high printing efficiency and accuracy.…”

Recent Progress in Additive Manufacturing of Fiber Reinforced Polymer Composite

“…Discontinuous Fibers : Thermoplastics such as PLA and thermosets such as acrylic‐based and epoxy‐based resins have been used as the matrix material . So far, the reinforcement exists only in form of discontinuous fibers like silicon carbide (SiC) whiskers, carbon fibers, glass fibers,[49a] and CNT . Reinforcement materials are mixed homogeneously with liquid resin to form paste‐like composite feedstock.…”

Design and Manufacture of Optimized Continuous Composite Fiber Filament Using Additive Manufacturing Systems

“…Griffini, Invernizzi and Natale developed a UV-Assisted 3D printing of glass (GFR) and carbon fiber reinforced (CFR) dual-core polymer composite [11]. In this work a sequential interpenetrating polymer network (IPN) obtained by formulating a photocurable acrylic resin with a thermo-curable epoxy resin was presented and proposed as matrix for the fabrication of GFR and CFR composite structures by means of 3D printing technology.…”

“…A need for improved tensile strength has driven a recent interest in AM of fiber reinforced polymers (FRPs). AM-FRPs are separated into two different families; short fiber reinforcement [6], and continuous long fiber reinforcement [7][8][9][10][11][12][13]. AM-FRPs reinforced with short fibers have demonstrated increased mechanical strength, but with limited design and structural flexibility.…”