Background
In the vast realm of advanced manufacturing technologies, continuous fiber manufacturing (CFM) has the capacity to fabricate structures characterized by their intricate complexity, lightweight, and exceptional properties. Most of CFM is developed based on the extrusion process, such as fused deposition modeling (FDM) and direct ink writing (DIW), to achieve the fabrication of polymer matrix with continuous fibers for overall performance reinforcement.
FDM is a common 3D printing technique where a melted plastic filament is deposited layer by layer to build an object. DIW is another 3D printing technique that precisely deposits a liquid “ink” to create structures.
However, the final products using these techniques currently have significant problems like delamination between strands or layers, voids that should not be there, and a lack of adherence from the liquid material to itself (fiber-to-matrix wetting).
Vat photopolymerization (VPP) is a 3D printing technique that uses light to cure liquid resin into solid objects. Continuous fiber writing includes reinforcing fibers like carbon fiber, fiberglass, or Kevlar to create an overall stronger and stiffer final product. Encapsulation involves taking one material and surrounding it with another.
Invention Description
Researchers at Arizona State University have developed a 3D printing method for the three fiber patterns (Weaving, Knitting, and Waving) using VPP, continuous fiber writing, and encapsulation to solve current challenges. This method involves printing pillar substrates strategically and writing continuous fibers around the pillar array. In initial tests, this method showed considerable improvements in maximum stress and ultimate strain, as well as flexibility in fabricating both single and multi-fiber embedded structures with complex geometries.
Potential Applications:
- Mechanical metamaterial
- Dynamic actuation
- Thermal management
- Smart optics
- 3D electronics
- Advanced sensor systems
Benefits and Advantages:
- Enhanced mechanical properties including an increased capability of maximum stress and ultimate strain compared to pure polymer
- Significant improvements in bonding between layers and between polymer matrix and fibers
- No porosity defects or incomplete fiber interface
- Rapid response rates (with less errors)