Novel Processing Methods for Introducing Short Fibers into Thermoset Resin Systems for Additive Manufacturing

Additive manufacturing (AM) is a field involving fabrication of complex parts using a variety technologies; however, AM’s broader implementation in industry and commercial settings is currently limited by the inferior mechanical properties of the produced parts when compared to those produced by traditional methods. To increase the strength of the parts produced, reinforcement such as short glass or carbon fiber must be introduced in a manner that has low unit operation and labor costs. 

This effort is centered around two distinct, prevalent AM technologies: direct ink writing (DIW) and direct light processing 3D printing (DLP). For the DIW portion of this work, I formulate bulk molding compounds (BMCs) and attempt to extrude them through large diameter nozzles, forming filaments that are then consolidated layer by layer to form a complex 3D structure. In the DLP space, I have built a novel, air-powered short fiber separation device that separating bundles of fibers into single fibers to deliver into a resin vat of a DLP printer. The printer is specially designed to accept and consolidate fibers in discrete steps.