Carbon Fiber and Syntactic Foam Hybrid Materials via Core–Shell Material Extrusion Additive Manufacturing

Robert C. Pack, Stian K. Romberg, Aly A. Badran, Nadim S. Hmeidat, Trenton Yount, Brett G. Compton

Research output: Contribution to journalArticlepeer-review

13 Scopus citations

Abstract

Biological materials often employ hybrid architectures, such as the core–shell (C–S) motif present in porcupine quills and plant stems, to achieve unique specific properties and performance. Drawing inspiration from these natural materials, a new method to fabricate lightweight and stiff C–S architected filaments is reported. Specifically, a C–S printhead conducive to printing highly loaded fiber-filled inks, as well as a new low-density syntactic foam ink, are utilized to 3D-print C–S architectures consisting of a syntactic epoxy foam core surrounded by a stiff carbon fiber-reinforced epoxy composite shell. Effective printing of test specimens and structures with controlled geometry, composition, and architecture is demonstrated. The new foam ink exhibits density as low as 0.68 g cm−3 and C–S structures exhibit up to 25% higher specific flexural stiffness (E1/3/ρ) than either constituent alone. Finally, a new mechanical model is presented to predict this performance improvement while accounting for potential eccentricity of the core.

Original languageEnglish
Article number2000731
JournalAdvanced Materials Technologies
Volume5
Issue number12
DOIs
StatePublished - Dec 2020
Externally publishedYes

Keywords

  • 3D printing
  • additive manufacturing
  • composites
  • core–shell hybrid materials
  • syntactic foams

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