Researchers at Colorado State University have developed an additive manufacturing technique to manufacture tooling (molds) for composite manufacturing, where the heat for curing of composites is produced by the mold itself.
The novel technique takes advantage of the simultaneous printing and curing of certain thermoset resin systems (e.g., epoxies, polyurethanes, cyclic olefins, etc.) in addition to highly customizable direct write vicious extrusion methods to manufacture novel self-heating thermoset composite tooling with high glass transition temperature (Tg). This new tooling design offers rapid and flexible design and manufacturing of high-performance tooling, eliminates the need for expensive resources (i.e., ovens and autoclaves), and can make composite manufacturing more accessible, energy-efficient, and cost-effective.
Fiber-reinforced polymer composites (FRPCs) are integral to aerospace, automotive, marine, biomedical, sports, construction, and energy industries owing to their excellent mechanical properties and low density. Conventional manufacture of FRPC components requires the matrix thermoset resin to be polymerized (cured) at elevated temperatures for several hours using large autoclaves or ovens that scale in size with the component.
The traditional manufacturing approach is therefore energy-inefficient and involves significant capital investment (i.e., access to large autoclaves and ovens). Manufacture of FRPC structures with non-planar geometries is particularly challenging because detailed mold and process design are often required for every new design, leading to long lead times and high manufacturing cost.
Recently, additive manufacturing techniques, which offer flexible and customizable design of 3D objects, have been used to make tooling for composite manufacturing. However, the materials used in tooling development typically have low thermal stability, making them unsuitable for high temperature curing of composites.
Licensed
US Patent Pending
Mostafa Yourdkhani