Experimental studies for the additive manufacturing of continuous fiber reinforced composites using UV-curing thermosets

Research output: Contribution to book/conference proceedings/anthology/reportConference contributionContributedpeer-review

Abstract

The economical production of lightweight structures with tailor-made properties and load-adapted geometry is limited using conventional technologies. Additive manufacturing processes offer a high potential to meet these requirements, where the established solutions are based primarily on thermoplastics matrix systems. From a process-technological point of view, thermoplastics enable simplified processing, but only a limited range of applications for high-performance components. These limitations are due to their comparatively low heat resistance, low melting temperatures and limited adhesion to embedded reinforcing fibers. In contrast, thermosets show high potential for realization of high- performance lightweight structures with adaptable properties. The present work employs a UV-curing thermoset resin for the impregnation of a continuous filament strand for 3D printing. The main challenge is to reconcile the crosslinking reaction of the thermoset and the process velocity during impregnation and cure. The liquid polymer must provide low initial viscosity to impregnate the filaments and a sufficiently high cure rate and dimensional stability after discharge from the print head to ensure sufficient bonding strength to the substrate. To demonstrate feasibility, a prototypic print head with UV-LED activation was designed and implemented. With a robot-guided printing platform, the 3D-deposition of continuous fiber-reinforcements without additional supporting structures can be realized. To derive initial process parameters, reaction and thermos-mechanical properties are determined by rheometer measurements. Impregnation and cure behavior of the glass fiber reinforced resin is investigated. The presented results provide a reliable process window and a straightforward process monitoring method for further enhancement of the conceived 3D printing process.

Details

Original languageEnglish
Title of host publicationProceedings ESAFORM 2021
Place of PublicationLiège, Belgique
Publication statusPublished - 8 Apr 2021
Peer-reviewedYes

Conference

Title24th International ESAFORM Conference on Material Forming
Abbreviated titleESAFORM 2021
Conference number24
Duration14 - 16 April 2021
Website
Degree of recognitionInternational event
Locationonline
CityLiège
CountryBelgium

External IDs

Scopus 85119362362
ORCID /0000-0003-0428-5341/work/142234877
ORCID /0000-0003-1370-064X/work/142243422
ORCID /0000-0003-3624-3242/work/142255786

Keywords

Keywords

  • Additive Manufacturing, UV-Curing, Thermosets, Continuous Fiber Reinforcement