Photo-Curing 3D Printing of Thermosetting Sacrificial Tooling for Fabricating Fiber-Reinforced Hollow Composites

Zhao, Baoming; Hao, Cheng; Chang, Yu‐Chung; Cao, Yiding; Liu, Tuan; Fei, Mingen; Shao, Lin; Zhang, Jinwen

doi:10.1002/adfm.202213663

Photo-Curing 3D Printing of Thermosetting Sacrificial Tooling for Fabricating Fiber-Reinforced Hollow Composites

Journal Article · Sun Feb 26 00:00:00 EST 2023 · Advanced Functional Materials

DOI:https://doi.org/10.1002/adfm.202213663· OSTI ID:2418708

^[1]; Hao, Cheng ^[2]; Chang, Yu‐Chung ^[2]; Cao, Yiding ^[2]; Liu, Tuan ^[2]; Fei, Mingen ^[2]; Shao, Lin ^[2]; ^[2]

Washington State Univ., Pullman, WA (United States); OSTI
Washington State Univ., Pullman, WA (United States)

Carbon fiber-reinforced hollow composites play a vital role in lightweighting modern cars and aircrafts. Fabrication of such hollow composites with seamless internal finish requires sacrificial tooling that can be used under pressure and high temperature. For the very first time, high performance sacrificial tooling that can be used to fabricate fiber-reinforced hollow composites is produced using photocuring 3D printing technology. This is achieved by developing UV-curable resins containing highly soluble yet hydrolysable acetal acrylate cross-linker and hydrophilic 4-acryloylmorpholine monomer. It is found that the cross-linker content greatly affects the printing speed. Further, the widely adopted UV post-curing method is found to have negligible impact on improving the thermal-mechanical properties of printed structures. Additionally, after thermal post-treatment, printed sacrificial tooling exhibits a heat deflection temperature of 112 °C at 0.455 MPa and an average coefficient of linear thermal expansion of 59 ppm °C^-1 between 30 and 100 °C. As a result, printed tooling enables fabrication of carbon fiber-reinforced hollow composites with complex geometry, which shows a tensile strength of 802 MPa and an elastic modulus of 50.2 GPa.

View Accepted Manuscript (DOE)

Research Organization:: Washington State Univ., Pullman, WA (United States)

Sponsoring Organization:: USDA; USDOE; USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: EE0008931

OSTI ID:: 2418708

Alternate ID(s):: OSTI ID: 1973552

Journal Information:: Advanced Functional Materials, Journal Name: Advanced Functional Materials Journal Issue: 20 Vol. 33; ISSN 1616-301X

Publisher:: WileyCopyright Statement

Country of Publication:: United States

Language:: English

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