Hybrid direct ink write 3D printing of high-performance composite structures
Purpose Direct ink writing (DIW) is a robust additive manufacturing technology for the fabrication of fiber-reinforced thermoset composites. However, this technique is currently limited to low design complexity and minimal heights. This study aims to investigate the feasibility of UV-assisted DIW of...
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| Veröffentlicht in: | Rapid prototyping journal 2023-04, Vol.29 (4), p.828-836 |
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| creator | Gonzalez, Juan Esteban Aponte Wright, William Jordan Gustinvil, Raden Celik, Emrah |
| description | Purpose
Direct ink writing (DIW) is a robust additive manufacturing technology for the fabrication of fiber-reinforced thermoset composites. However, this technique is currently limited to low design complexity and minimal heights. This study aims to investigate the feasibility of UV-assisted DIW of composites to enhance the green-part strength of the printed inks and resolve the complexity and the height limitations of DIW technology.
Design/methodology/approach
The experimental approach involved the preparation of the thermoset inks that are composed of nanoclay, epoxy, photopolymer and glass fiber reinforcement. Composite specimens were fabricated in complex geometries from these ink feedstocks using UV-assisted, hybrid 3D-printing technology. Fabricated specimens were characterized using optical microscopy, three-point bending mechanical tests and numerical simulations.
Findings
The introduced hybrid, UV-assisted 3D-printing technology allowed the fabrication of tall and overhanging thermoset composite structures up to 30% glass fiber reinforcement without sagging during or after printing. Glass fiber reinforcement tremendously enhanced the mechanical performance of the composites. UV-curable resin addition led to a reduction in strength (approximately 15%) compared to composites fabricated without UV resin. However, this reduction can be eliminated by increasing the glass fiber content within the hybrid thermoset composite. Numerical simulations indicate that the fiber orientation significantly affects the mechanical performance of the printed composites.
Originality/value
This study showed that the fabrication of high-performing thermoset composites in complex geometries was possible via hybrid DIW technology. This new technology will tremendously expand the application envelope of the additively manufactured thermoset composites and the fabrication of large composite structures with high mechanical performance and dimensional freedom will benefit various engineering fields including the fields of aerospace, automotive and marine engineering. |
| doi_str_mv | 10.1108/RPJ-12-2021-0341 |
| format | Article |
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Direct ink writing (DIW) is a robust additive manufacturing technology for the fabrication of fiber-reinforced thermoset composites. However, this technique is currently limited to low design complexity and minimal heights. This study aims to investigate the feasibility of UV-assisted DIW of composites to enhance the green-part strength of the printed inks and resolve the complexity and the height limitations of DIW technology.
Design/methodology/approach
The experimental approach involved the preparation of the thermoset inks that are composed of nanoclay, epoxy, photopolymer and glass fiber reinforcement. Composite specimens were fabricated in complex geometries from these ink feedstocks using UV-assisted, hybrid 3D-printing technology. Fabricated specimens were characterized using optical microscopy, three-point bending mechanical tests and numerical simulations.
Findings
The introduced hybrid, UV-assisted 3D-printing technology allowed the fabrication of tall and overhanging thermoset composite structures up to 30% glass fiber reinforcement without sagging during or after printing. Glass fiber reinforcement tremendously enhanced the mechanical performance of the composites. UV-curable resin addition led to a reduction in strength (approximately 15%) compared to composites fabricated without UV resin. However, this reduction can be eliminated by increasing the glass fiber content within the hybrid thermoset composite. Numerical simulations indicate that the fiber orientation significantly affects the mechanical performance of the printed composites.
Originality/value
This study showed that the fabrication of high-performing thermoset composites in complex geometries was possible via hybrid DIW technology. This new technology will tremendously expand the application envelope of the additively manufactured thermoset composites and the fabrication of large composite structures with high mechanical performance and dimensional freedom will benefit various engineering fields including the fields of aerospace, automotive and marine engineering.</description><identifier>ISSN: 1355-2546</identifier><identifier>EISSN: 1758-7670</identifier><identifier>EISSN: 1355-2546</identifier><identifier>DOI: 10.1108/RPJ-12-2021-0341</identifier><language>eng</language><publisher>Bradford: Emerald Publishing Limited</publisher><subject>3-D printers ; Additive manufacturing ; Aerospace engineering ; Automotive engineering ; Carbon fibers ; Complexity ; Composite materials ; Composite structures ; Curing ; Fiber composites ; Fiber orientation ; Fiber reinforced polymers ; Fiber reinforcement ; Glass fiber reinforced plastics ; Glass-epoxy composites ; Inks ; Lasers ; Marine engineering ; Mechanical properties ; Mechanical tests ; New technology ; Optical microscopy ; Photopolymers ; Printing ; Rapid prototyping ; Reduction ; Resins ; Robustness (mathematics) ; Three dimensional composites ; Three dimensional printing ; Ultraviolet radiation ; Viscosity</subject><ispartof>Rapid prototyping journal, 2023-04, Vol.29 (4), p.828-836</ispartof><rights>Emerald Publishing Limited</rights><rights>Emerald Publishing Limited.</rights><lds50>peer_reviewed</lds50><woscitedreferencessubscribed>false</woscitedreferencessubscribed><citedby>FETCH-LOGICAL-c311t-1110f10d0e6710dc2bdec6889e3520b0bd7bf653e8ccd30a2c062cdf2a1c660a3</citedby><cites>FETCH-LOGICAL-c311t-1110f10d0e6710dc2bdec6889e3520b0bd7bf653e8ccd30a2c062cdf2a1c660a3</cites></display><links><openurl>$$Topenurl_article</openurl><openurlfulltext>$$Topenurlfull_article</openurlfulltext><thumbnail>$$Tsyndetics_thumb_exl</thumbnail><linktohtml>$$Uhttps://www.emerald.com/insight/content/doi/10.1108/RPJ-12-2021-0341/full/html$$EHTML$$P50$$Gemerald$$H</linktohtml><link.rule.ids>314,776,780,21675,27903,27904,53222</link.rule.ids></links><search><creatorcontrib>Gonzalez, Juan Esteban Aponte</creatorcontrib><creatorcontrib>Wright, William Jordan</creatorcontrib><creatorcontrib>Gustinvil, Raden</creatorcontrib><creatorcontrib>Celik, Emrah</creatorcontrib><title>Hybrid direct ink write 3D printing of high-performance composite structures</title><title>Rapid prototyping journal</title><description>Purpose
Direct ink writing (DIW) is a robust additive manufacturing technology for the fabrication of fiber-reinforced thermoset composites. However, this technique is currently limited to low design complexity and minimal heights. This study aims to investigate the feasibility of UV-assisted DIW of composites to enhance the green-part strength of the printed inks and resolve the complexity and the height limitations of DIW technology.
Design/methodology/approach
The experimental approach involved the preparation of the thermoset inks that are composed of nanoclay, epoxy, photopolymer and glass fiber reinforcement. Composite specimens were fabricated in complex geometries from these ink feedstocks using UV-assisted, hybrid 3D-printing technology. Fabricated specimens were characterized using optical microscopy, three-point bending mechanical tests and numerical simulations.
Findings
The introduced hybrid, UV-assisted 3D-printing technology allowed the fabrication of tall and overhanging thermoset composite structures up to 30% glass fiber reinforcement without sagging during or after printing. Glass fiber reinforcement tremendously enhanced the mechanical performance of the composites. UV-curable resin addition led to a reduction in strength (approximately 15%) compared to composites fabricated without UV resin. However, this reduction can be eliminated by increasing the glass fiber content within the hybrid thermoset composite. Numerical simulations indicate that the fiber orientation significantly affects the mechanical performance of the printed composites.
Originality/value
This study showed that the fabrication of high-performing thermoset composites in complex geometries was possible via hybrid DIW technology. This new technology will tremendously expand the application envelope of the additively manufactured thermoset composites and the fabrication of large composite structures with high mechanical performance and dimensional freedom will benefit various engineering fields including the fields of aerospace, automotive and marine engineering.</description><subject>3-D printers</subject><subject>Additive manufacturing</subject><subject>Aerospace engineering</subject><subject>Automotive engineering</subject><subject>Carbon fibers</subject><subject>Complexity</subject><subject>Composite materials</subject><subject>Composite structures</subject><subject>Curing</subject><subject>Fiber composites</subject><subject>Fiber orientation</subject><subject>Fiber reinforced polymers</subject><subject>Fiber reinforcement</subject><subject>Glass fiber reinforced plastics</subject><subject>Glass-epoxy composites</subject><subject>Inks</subject><subject>Lasers</subject><subject>Marine engineering</subject><subject>Mechanical properties</subject><subject>Mechanical tests</subject><subject>New technology</subject><subject>Optical microscopy</subject><subject>Photopolymers</subject><subject>Printing</subject><subject>Rapid prototyping</subject><subject>Reduction</subject><subject>Resins</subject><subject>Robustness (mathematics)</subject><subject>Three dimensional composites</subject><subject>Three dimensional printing</subject><subject>Ultraviolet radiation</subject><subject>Viscosity</subject><issn>1355-2546</issn><issn>1758-7670</issn><issn>1355-2546</issn><fulltext>true</fulltext><rsrctype>article</rsrctype><creationdate>2023</creationdate><recordtype>article</recordtype><sourceid>AFKRA</sourceid><sourceid>BENPR</sourceid><sourceid>CCPQU</sourceid><sourceid>DWQXO</sourceid><recordid>eNptkEtPwzAQhC0EEqVw52iJs-munTjpERVoQZVACM5W4keb0jywE6H-exyVCxKn2cPM7s5HyDXCLSLks7fXZ4acceDIQCR4QiaYpTnLZAancRZpyniayHNyEcIOAHmSwoSsV4fSV4aaylvd06r5pN--6i0V97TzVdNXzYa2jm6rzZZ11rvW10WjLdVt3bVhdIbeD7ofvA2X5MwV-2CvfnVKPh4f3hcrtn5ZPi3u1kwLxJ5hfNghGLAyi6J5aayWeT63IuVQQmmy0slU2FxrI6DgGiTXxvECtZRQiCm5Oe7tfPs12NCrXTv4Jp5UPJvznOcZJNEFR5f2bQjeOhUL1YU_KAQ1MlORmUKuRmZqZBYjs2PE1tYXe_Nf4g9l8QMOSm1E</recordid><startdate>20230404</startdate><enddate>20230404</enddate><creator>Gonzalez, Juan Esteban Aponte</creator><creator>Wright, William Jordan</creator><creator>Gustinvil, Raden</creator><creator>Celik, Emrah</creator><general>Emerald Publishing Limited</general><general>Emerald Group Publishing Limited</general><scope>AAYXX</scope><scope>CITATION</scope><scope>0U~</scope><scope>1-H</scope><scope>7TB</scope><scope>7WY</scope><scope>7WZ</scope><scope>7XB</scope><scope>8AO</scope><scope>8FD</scope><scope>8FE</scope><scope>8FG</scope><scope>ABJCF</scope><scope>AFKRA</scope><scope>BENPR</scope><scope>BEZIV</scope><scope>BGLVJ</scope><scope>CCPQU</scope><scope>DWQXO</scope><scope>FR3</scope><scope>F~G</scope><scope>HCIFZ</scope><scope>K6~</scope><scope>L.-</scope><scope>L.0</scope><scope>L6V</scope><scope>M0C</scope><scope>M7S</scope><scope>PQBIZ</scope><scope>PQEST</scope><scope>PQQKQ</scope><scope>PQUKI</scope><scope>PTHSS</scope><scope>Q9U</scope><scope>S0W</scope></search><sort><creationdate>20230404</creationdate><title>Hybrid direct ink write 3D printing of high-performance composite structures</title><author>Gonzalez, Juan Esteban Aponte ; Wright, William Jordan ; Gustinvil, Raden ; Celik, Emrah</author></sort><facets><frbrtype>5</frbrtype><frbrgroupid>cdi_FETCH-LOGICAL-c311t-1110f10d0e6710dc2bdec6889e3520b0bd7bf653e8ccd30a2c062cdf2a1c660a3</frbrgroupid><rsrctype>articles</rsrctype><prefilter>articles</prefilter><language>eng</language><creationdate>2023</creationdate><topic>3-D printers</topic><topic>Additive manufacturing</topic><topic>Aerospace engineering</topic><topic>Automotive engineering</topic><topic>Carbon fibers</topic><topic>Complexity</topic><topic>Composite materials</topic><topic>Composite structures</topic><topic>Curing</topic><topic>Fiber composites</topic><topic>Fiber orientation</topic><topic>Fiber reinforced polymers</topic><topic>Fiber reinforcement</topic><topic>Glass fiber reinforced plastics</topic><topic>Glass-epoxy composites</topic><topic>Inks</topic><topic>Lasers</topic><topic>Marine engineering</topic><topic>Mechanical properties</topic><topic>Mechanical tests</topic><topic>New technology</topic><topic>Optical microscopy</topic><topic>Photopolymers</topic><topic>Printing</topic><topic>Rapid prototyping</topic><topic>Reduction</topic><topic>Resins</topic><topic>Robustness (mathematics)</topic><topic>Three dimensional composites</topic><topic>Three dimensional printing</topic><topic>Ultraviolet radiation</topic><topic>Viscosity</topic><toplevel>peer_reviewed</toplevel><toplevel>online_resources</toplevel><creatorcontrib>Gonzalez, Juan Esteban Aponte</creatorcontrib><creatorcontrib>Wright, William Jordan</creatorcontrib><creatorcontrib>Gustinvil, Raden</creatorcontrib><creatorcontrib>Celik, Emrah</creatorcontrib><collection>CrossRef</collection><collection>Global News & ABI/Inform Professional</collection><collection>Trade PRO</collection><collection>Mechanical & Transportation Engineering Abstracts</collection><collection>ABI/INFORM Collection</collection><collection>ABI/INFORM Global (PDF only)</collection><collection>ProQuest Central (purchase pre-March 2016)</collection><collection>ProQuest Pharma Collection</collection><collection>Technology Research Database</collection><collection>ProQuest SciTech Collection</collection><collection>ProQuest Technology Collection</collection><collection>Materials Science & Engineering Collection</collection><collection>ProQuest Central UK/Ireland</collection><collection>ProQuest Central</collection><collection>Business Premium Collection</collection><collection>Technology Collection</collection><collection>ProQuest One Community College</collection><collection>ProQuest Central Korea</collection><collection>Engineering Research Database</collection><collection>ABI/INFORM Global (Corporate)</collection><collection>SciTech Premium Collection</collection><collection>ProQuest Business Collection</collection><collection>ABI/INFORM Professional Advanced</collection><collection>ABI/INFORM Professional Standard</collection><collection>ProQuest Engineering Collection</collection><collection>ABI/INFORM global</collection><collection>Engineering Database</collection><collection>One Business</collection><collection>ProQuest One Academic Eastern Edition (DO NOT USE)</collection><collection>ProQuest One Academic</collection><collection>ProQuest One Academic UKI Edition</collection><collection>Engineering collection</collection><collection>ProQuest Central Basic</collection><collection>DELNET Engineering & Technology Collection</collection><jtitle>Rapid prototyping journal</jtitle></facets><delivery><delcategory>Remote Search Resource</delcategory><fulltext>fulltext</fulltext></delivery><addata><au>Gonzalez, Juan Esteban Aponte</au><au>Wright, William Jordan</au><au>Gustinvil, Raden</au><au>Celik, Emrah</au><format>journal</format><genre>article</genre><ristype>JOUR</ristype><atitle>Hybrid direct ink write 3D printing of high-performance composite structures</atitle><jtitle>Rapid prototyping journal</jtitle><date>2023-04-04</date><risdate>2023</risdate><volume>29</volume><issue>4</issue><spage>828</spage><epage>836</epage><pages>828-836</pages><issn>1355-2546</issn><eissn>1758-7670</eissn><eissn>1355-2546</eissn><abstract>Purpose
Direct ink writing (DIW) is a robust additive manufacturing technology for the fabrication of fiber-reinforced thermoset composites. However, this technique is currently limited to low design complexity and minimal heights. This study aims to investigate the feasibility of UV-assisted DIW of composites to enhance the green-part strength of the printed inks and resolve the complexity and the height limitations of DIW technology.
Design/methodology/approach
The experimental approach involved the preparation of the thermoset inks that are composed of nanoclay, epoxy, photopolymer and glass fiber reinforcement. Composite specimens were fabricated in complex geometries from these ink feedstocks using UV-assisted, hybrid 3D-printing technology. Fabricated specimens were characterized using optical microscopy, three-point bending mechanical tests and numerical simulations.
Findings
The introduced hybrid, UV-assisted 3D-printing technology allowed the fabrication of tall and overhanging thermoset composite structures up to 30% glass fiber reinforcement without sagging during or after printing. Glass fiber reinforcement tremendously enhanced the mechanical performance of the composites. UV-curable resin addition led to a reduction in strength (approximately 15%) compared to composites fabricated without UV resin. However, this reduction can be eliminated by increasing the glass fiber content within the hybrid thermoset composite. Numerical simulations indicate that the fiber orientation significantly affects the mechanical performance of the printed composites.
Originality/value
This study showed that the fabrication of high-performing thermoset composites in complex geometries was possible via hybrid DIW technology. This new technology will tremendously expand the application envelope of the additively manufactured thermoset composites and the fabrication of large composite structures with high mechanical performance and dimensional freedom will benefit various engineering fields including the fields of aerospace, automotive and marine engineering.</abstract><cop>Bradford</cop><pub>Emerald Publishing Limited</pub><doi>10.1108/RPJ-12-2021-0341</doi><tpages>9</tpages></addata></record> |
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| identifier | ISSN: 1355-2546 |
| ispartof | Rapid prototyping journal, 2023-04, Vol.29 (4), p.828-836 |
| issn | 1355-2546 1758-7670 1355-2546 |
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| source | Emerald Insight |
| subjects | 3-D printers Additive manufacturing Aerospace engineering Automotive engineering Carbon fibers Complexity Composite materials Composite structures Curing Fiber composites Fiber orientation Fiber reinforced polymers Fiber reinforcement Glass fiber reinforced plastics Glass-epoxy composites Inks Lasers Marine engineering Mechanical properties Mechanical tests New technology Optical microscopy Photopolymers Printing Rapid prototyping Reduction Resins Robustness (mathematics) Three dimensional composites Three dimensional printing Ultraviolet radiation Viscosity |
| title | Hybrid direct ink write 3D printing of high-performance composite structures |
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