Here, we demonstrate a stereolithography-inspired additive manufacturing method to fabricate high strength and stiffness continuous carbon fiber reinforced composites. Woven carbon fiber fabric was laser cut to desired geometries resulting in high-resolution composite fabrication. An aerospace grade dual-curable photopolymer resin was used as a high-performance matrix material and was impregnated into carbon fiber fabric with a heated resin bath. Following impregnation, compression-consolidation with a FEP lined glass plate and custom fixture minimized porosity and enabled control over the resultant fiber volume fraction. Ultraviolet-curing of the photopolymer-infused composite enabled multi-layer printing in a semi-cured state, while thermal post curing was utilized to reach the final properties. This process resulted in 3D printed woven composites with a fiber volume fraction of 39%. With woven fiber reinforcement there was a 2.8 times increase in flexural strength, and 3.0 times increase in flexural modulus over unreinforced counterparts. Microstructural characterization revealed the benefits of resin-infusion and consolidation by improving densification. Due to the use of a glass consolidation plate, this process resulted in 3D printed woven composites with an excellent surface finish with very low surface roughness approaching that of vat polymerization processes.

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3D Printing of Woven Carbon Fiber Composites Via a Stereolithography-Inspired Technique with Consolidation

  • John M. Pappas,
  • Xiangyang Dong

摘要

Here, we demonstrate a stereolithography-inspired additive manufacturing method to fabricate high strength and stiffness continuous carbon fiber reinforced composites. Woven carbon fiber fabric was laser cut to desired geometries resulting in high-resolution composite fabrication. An aerospace grade dual-curable photopolymer resin was used as a high-performance matrix material and was impregnated into carbon fiber fabric with a heated resin bath. Following impregnation, compression-consolidation with a FEP lined glass plate and custom fixture minimized porosity and enabled control over the resultant fiber volume fraction. Ultraviolet-curing of the photopolymer-infused composite enabled multi-layer printing in a semi-cured state, while thermal post curing was utilized to reach the final properties. This process resulted in 3D printed woven composites with a fiber volume fraction of 39%. With woven fiber reinforcement there was a 2.8 times increase in flexural strength, and 3.0 times increase in flexural modulus over unreinforced counterparts. Microstructural characterization revealed the benefits of resin-infusion and consolidation by improving densification. Due to the use of a glass consolidation plate, this process resulted in 3D printed woven composites with an excellent surface finish with very low surface roughness approaching that of vat polymerization processes.