skip to main content
OSTI.GOV title logo U.S. Department of Energy
Office of Scientific and Technical Information

Title: Additive manufacturing of short and mixed fibre-reinforced polymer

Abstract

Additive manufacturing of a fiber-reinforced polymer (FRP) product using an additive manufacturing print head; a reservoir in the additive manufacturing print head; short carbon fibers in the reservoir, wherein the short carbon fibers are randomly aligned in the reservoir; an acrylate, methacrylate, epoxy, cyanate ester or isocyanate resin in the reservoir, wherein the short carbon fibers are dispersed in the acrylate, methacrylate, epoxy, cyanate ester or isocyanate resin; a tapered nozzle in the additive manufacturing print head operatively connected to the reservoir, the tapered nozzle produces an extruded material that forms the fiber-reinforced polymer product; baffles in the tapered nozzle that receive the acrylate, methacrylate, epoxy, cyanate ester or isocyanate resin with the short carbon fibers dispersed in the acrylate, methacrylate, epoxy, cyanate ester or isocyanate resin; and a system for driving the acrylate, methacrylate, epoxy, cyanate ester or isocyanate resin with the short carbon fibers dispersed in the acrylate, methacrylate, epoxy, cyanate ester or isocyanate resin from the reservoir through the tapered nozzle wherein the randomly aligned short carbon fibers in the acrylate, methacrylate, epoxy, cyanate ester or isocyanate resin are aligned by the baffles and wherein the extruded material has the short carbon fibers aligned in the acrylate,more » methacrylate, epoxy, cyanate ester or isocyanate resin that forms the fiber-reinforced polymer product.« less

Inventors:
; ; ; ;
Publication Date:
Research Org.:
Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
1416736
Patent Number(s):
9,862,140
Application Number:
14/802,105
Assignee:
Lawrence Livermore National Security, LLC (Livermore, CA) LLNL
DOE Contract Number:
AC52-07NA27344
Resource Type:
Patent
Resource Relation:
Patent File Date: 2015 Jul 17
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; 42 ENGINEERING

Citation Formats

Lewicki, James, Duoss, Eric B., Rodriguez, Jennifer Nicole, Worsley, Marcus A., and King, Michael J.. Additive manufacturing of short and mixed fibre-reinforced polymer. United States: N. p., 2018. Web.
Lewicki, James, Duoss, Eric B., Rodriguez, Jennifer Nicole, Worsley, Marcus A., & King, Michael J.. Additive manufacturing of short and mixed fibre-reinforced polymer. United States.
Lewicki, James, Duoss, Eric B., Rodriguez, Jennifer Nicole, Worsley, Marcus A., and King, Michael J.. 2018. "Additive manufacturing of short and mixed fibre-reinforced polymer". United States. doi:. https://www.osti.gov/servlets/purl/1416736.
@article{osti_1416736,
title = {Additive manufacturing of short and mixed fibre-reinforced polymer},
author = {Lewicki, James and Duoss, Eric B. and Rodriguez, Jennifer Nicole and Worsley, Marcus A. and King, Michael J.},
abstractNote = {Additive manufacturing of a fiber-reinforced polymer (FRP) product using an additive manufacturing print head; a reservoir in the additive manufacturing print head; short carbon fibers in the reservoir, wherein the short carbon fibers are randomly aligned in the reservoir; an acrylate, methacrylate, epoxy, cyanate ester or isocyanate resin in the reservoir, wherein the short carbon fibers are dispersed in the acrylate, methacrylate, epoxy, cyanate ester or isocyanate resin; a tapered nozzle in the additive manufacturing print head operatively connected to the reservoir, the tapered nozzle produces an extruded material that forms the fiber-reinforced polymer product; baffles in the tapered nozzle that receive the acrylate, methacrylate, epoxy, cyanate ester or isocyanate resin with the short carbon fibers dispersed in the acrylate, methacrylate, epoxy, cyanate ester or isocyanate resin; and a system for driving the acrylate, methacrylate, epoxy, cyanate ester or isocyanate resin with the short carbon fibers dispersed in the acrylate, methacrylate, epoxy, cyanate ester or isocyanate resin from the reservoir through the tapered nozzle wherein the randomly aligned short carbon fibers in the acrylate, methacrylate, epoxy, cyanate ester or isocyanate resin are aligned by the baffles and wherein the extruded material has the short carbon fibers aligned in the acrylate, methacrylate, epoxy, cyanate ester or isocyanate resin that forms the fiber-reinforced polymer product.},
doi = {},
journal = {},
number = ,
volume = ,
place = {United States},
year = 2018,
month = 1
}

Patent:

Save / Share:
  • ORNL worked with American Process Inc. to demonstrate the potential use of bio-based BioPlus ┬« lignin-coated cellulose nanofibrils (L-CNF) as a reinforcing agent in the development of polymer feedstock suitable for additive manufacturing. L-CNF-reinforced polylactic acid (PLA) testing coupons were prepared and up to 69% increase in tensile strength and 133% increase in elastic modulus were demonstrated.
  • A ceramic matrix for carbon fibre reinforced ceramic matrix composites (CMC) has been developed from polysiloxane/boron mixtures. Complex geometries can be realized by using processing technologies of fibre reinforced polymer composites. Upon pyrolysis the polymer/filler mixture is converted into a ceramic matrix consisting of SiC, B{sub 4}C, BN and a Si-O-C-(N) glass, without reacting with the carbon fibre. Due to the large volume increase of the reactive boron filler upon nitridation (+142 vol%) no multiple reinfiltration of the structure is necessary in order to achieve a dense matrix. Thermodynamic modelling of the pyrolysis is a useful tool to estimate themore » qualitative and quantitative phase composition as a function of polymer, filler and gas atmospheres.« less
  • Short fibres, whiskers or particles of ceramic materials, e.g. silicon carbide and alumina, when dispersed in a more or less random manner in a metallic matrix can promote increases in stiffness and strength at ambient and elevated temperatures without imposing a weight penalty. The paper considers the available routes for the fabrication of such composites, e.g. by squeeze casting, spray forming, powder technologies and hot working etc. Influences of type and amount of reinforcement, matrix alloy selection and processing route on strength, creep and fatigue resistance are discussed. Comparisons are made with conventional metals and alloys, and polymers and metalsmore » reinforced with continuous fibres. Attention is drawn to the behaviour of these materials under compressive loading as well as to their thermal expansion and conductivity. The majority of the matrices considered are aluminium-based.« less
  • A process for additive manufacture by energetic wire deposition is described. A source wire is fed into a energy beam generated melt-pool on a growth surface as the melt-pool moves over the growth surface. This process enables the rapid prototyping and manufacture of fully dense, near-net shape components, as well as cladding and welding processes. Alloys, graded materials, and other inhomogeneous materials can be grown using this process.