Abstract
Continuous fiber-reinforced thermoset matrix composite structures play an important role in modern aerospace design due to their extremely high attainable strength-to-weight ratio, but manufacturing processes are often prohibitively expensive for prototyping and small-scale production. This paper presents an additive manufacturing solution based on direct-ink-write technology using UV-curable thermosets to produce in-situ cured continuous fiber composite parts. In-situ UV cure gives this process potential for rapid prototyping in open-air settings, and the direct-ink-write method means it is simple enough to use in small-scale, low-cost applications. Thermosets and carbon fiber are used to show further potential to produce composites using aerospace-grade materials. The manufacturing process is capable of printing geometrically complex parts, like honeycombs, with no tool-up or specialty equipment. Tensile testing analyses of early samples show ultimate tensile strengths of 117 MPa and elastic moduli up to 15 GPa. Further analyses show printed parts having fiber volume fractions in the range of 8.3%. Higher strengths and fiber volume fractions are expected to be feasible as the process matures.
