Hybrid direct ink write 3D printing of high-performance composite structures

Purpose Direct ink writing (DIW) is a robust additive manufacturing technology for the fabrication of fiber-reinforced thermoset composites. However, this technique is currently limited to low design complexity and minimal heights. This study aims to investigate the feasibility of UV-assisted DIW of composites to enhance the green-part strength of the printed inks and resolve the complexity and the height limitations of DIW technology. Design/methodology/approach The experimental approach involved the preparation of the thermoset inks that are composed of nanoclay, epoxy, photopolymer and glass fiber reinforcement. Composite specimens were fabricated in complex geometries from these ink feedstocks using UV-assisted, hybrid 3D-printing technology. Fabricated specimens were characterized using optical microscopy, three-point bending mechanical tests and numerical simulations. Findings The introduced hybrid, UV-assisted 3D-printing technology allowed the fabrication of tall and overhanging thermoset composite structures up to 30% glass fiber reinforcement without sagging during or after printing. Glass fiber reinforcement tremendously enhanced the mechanical performance of the composites. UV-curable resin addition led to a reduction in strength (approximately 15%) compared to composites fabricated without UV resin. However, this reduction can be eliminated by increasing the glass fiber content within the hybrid thermoset composite. Numerical simulations indicate that the fiber orientation significantly affects the mechanical performance of the printed composites. Originality/value This study showed that the fabrication of high-performing thermoset composites in complex geometries was possible via hybrid DIW technology. This new technology will tremendously expand the application envelope of the additively manufactured thermoset composites and the fabrication of large composite structures with high mechanical performance and dimensional freedom will benefit various engineering fields including the fields of aerospace, automotive and marine engineering.