TY - GEN
T1 - CONTINUOUS FIBER 3D PRINTING FOR COMPRESSION OVER MOLDING
AU - Smith, Tyler
AU - Brackett, James
AU - Walker, Roo
AU - Kumar, Vipin
AU - Nuttall, David
AU - Ogle, Ryan
AU - Charron, Julian
AU - Duty, Chad
AU - Kunc, Vlastimil
AU - Hassen, Ahmed Arabi
N1 - Publisher Copyright:
Copyright © 2023. Used by CAMX - The Composites and Advanced Materials Expo. CAMX Conference Proceedings.
PY - 2023
Y1 - 2023
N2 - Due to fiber alignment along the deposition direction, additive manufacturing systems have the capability to produce parts with distinct anisotropic properties. Oak Ridge National Laboratory (ORNL) has developed an innovative Additive Manufacturing - Compression Molding (AM-CM) system that combines the advantages of AM and CM. By creating preforms using AM and subsequently utilizing CM, parts can be fabricated with optimized fiber alignment along the component. This advanced technology allows for the rapid production of parts, meeting the fast-rate process requirements of the automotive industry, with a cycle time of just three minutes. To further enhance the mechanical performance of these components, continuous fiber can be incorporated on top of the mold before the preforming process. Alternatively, the continuous fiber can be pre-printed separately and placed along the mold to over-mold it into the structure during CM. This fusion of materials during CM results in the creation of built-in stiffeners along the loading direction. These modifications enable the precise placement of continuous carbon fiber within the mold, achieving a bend radius that was previously unattainable through traditional methods. The introduction of these fibers has proven to significantly increase flexural strength by 57% and flexural modulus by 49%. Additionally, incorporating continuous fibers along the joints of several parts through over-molding enhances the strength between these components. In summary, the AM-CM system, combined with the integration of continuous carbon fibers, offers an innovative approach to fabricating high-performance parts with unique anisotropic properties, meeting the demands of the automotive industry and beyond.
AB - Due to fiber alignment along the deposition direction, additive manufacturing systems have the capability to produce parts with distinct anisotropic properties. Oak Ridge National Laboratory (ORNL) has developed an innovative Additive Manufacturing - Compression Molding (AM-CM) system that combines the advantages of AM and CM. By creating preforms using AM and subsequently utilizing CM, parts can be fabricated with optimized fiber alignment along the component. This advanced technology allows for the rapid production of parts, meeting the fast-rate process requirements of the automotive industry, with a cycle time of just three minutes. To further enhance the mechanical performance of these components, continuous fiber can be incorporated on top of the mold before the preforming process. Alternatively, the continuous fiber can be pre-printed separately and placed along the mold to over-mold it into the structure during CM. This fusion of materials during CM results in the creation of built-in stiffeners along the loading direction. These modifications enable the precise placement of continuous carbon fiber within the mold, achieving a bend radius that was previously unattainable through traditional methods. The introduction of these fibers has proven to significantly increase flexural strength by 57% and flexural modulus by 49%. Additionally, incorporating continuous fibers along the joints of several parts through over-molding enhances the strength between these components. In summary, the AM-CM system, combined with the integration of continuous carbon fibers, offers an innovative approach to fabricating high-performance parts with unique anisotropic properties, meeting the demands of the automotive industry and beyond.
KW - Additive manufacturing
KW - compression molding
KW - integrated manufacturing processes
KW - overmolding
UR - http://www.scopus.com/inward/record.url?scp=85188536260&partnerID=8YFLogxK
U2 - 10.33599/nasampe/c.23.0197
DO - 10.33599/nasampe/c.23.0197
M3 - Conference contribution
AN - SCOPUS:85188536260
T3 - Composites and Advanced Materials Expo, CAMX 2023
BT - Composites and Advanced Materials Expo, CAMX 2023
PB - The Composites and Advanced Materials Expo (CAMX)
T2 - 9th Annual Composites and Advanced Materials Expo, CAMX 2023
Y2 - 30 October 2023 through 2 November 2023
ER -