Hybrid direct ink write 3D printing of high-performance composite structures
ISSN: 1355-2546
Article publication date: 10 November 2022
Issue publication date: 4 April 2023
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.
Keywords
Acknowledgements
Declaration of interests: The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.
Citation
Gonzalez, J.E.A., Wright, W.J., Gustinvil, R. and Celik, E. (2023), "Hybrid direct ink write 3D printing of high-performance composite structures", Rapid Prototyping Journal, Vol. 29 No. 4, pp. 828-836. https://doi.org/10.1108/RPJ-12-2021-0341
Publisher
:Emerald Publishing Limited
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