CBAM: Composite-Based Additive Manufacturing€¦ · 3/3/2018 · Kevlar Carbon Fiber Fiberglass...
Transcript of CBAM: Composite-Based Additive Manufacturing€¦ · 3/3/2018 · Kevlar Carbon Fiber Fiberglass...
CBAM: Composite-Based Additive Manufacturing
CBAM-made Carbon Fiber Reinforced Plastic (CFRP) Parts
How CBAM works
Feed fiber
sheet into inkjet
printer.
17 GSM areal
weight for
nonwoven
sheets:
• Carbon
• Fiberglass
Load CAD
slices into
printer and use
600DPI inkjet
system to print
aqueous fluid
layer shape of
object on fiber
sheet
Deposit polymer
powder onto
printed sheet
which sticks to
where the sheet
is wet from print
fluid.
Powder particle
approximately
50 to 100 micron
Air knife and
vacuum to
remove dry
powder; only
powder stuck to
the print fluid
remains based
on weight
calculation of
20% carbon
and 80%
polymer
Stack sheets in
order, heat to
melting T° of
polymer, and
compress stack
to final part
height.
200◦C nylon 12
400◦C PEEK
Compaction
pressure 100 -
150 psi
Abrasive removal
of un-bonded
portions of sheet
fibers to net final
part.
60psi, 12 CFM
Abrasives
• Walnut shells
• Silicon carbide
#320
• Aluminum
Oxide #220
STEPS
Step 1 Step 2 Step 3 Step 4 Step 5 Step 6
Step 1
Print image on fiber sheets Step 2
Heat & Press
Step 3
Remove Part
4 Impossible Objects Confidential
Nonwoven Composite Materials
A nonwoven is a highly porous fiber sheet with tuneable properties
• Nonwoven composite veils and mats are composed of:
– Long (> 1’’ length) chopped engineered fibres
– Uniform, random fibres orientation
– Held together with a polymer binder
• Fiber type dictates properties, typical examples:
– Carbon, glass, aramid, polyester, metal-coated carbon, thermoplastics
Non-woven fiber veils
• Carbon Fiber
• Kevlar
• Fiberglass
Polymers Matrix Materials
• HDPE
• Nylons
• PEEK
• PEI and TPU (under evaluation)
NOTE:
PEI is a flame retardant resin has UL94 V0, V2 and 5VA ratings an is RoHS compliant
Option for a open material system allowing for third party materials
Kevlar
Carbon Fiber
Fiberglass
Build materials options
Co
st
Dri
ve
n
Pe
rfo
rma
nc
e D
rive
n
amorphous crystalline
Engineering
Polymers
High Performance
Polymers
PET PBT
POM PUR
PC PPE
Commodity
Polymers
PA4.6
PPA
PPS
LCP
FPs
PEEK
PA12
PA11
PAI
PPSU
PEI
PES
PSU
PAR PA612 Transp. PA
PA6 / PA66
PI
PVC
ABS
PS SAN
PE
PP
PMMA
PMMI
PMI
PE-LD PE-HD
High Performance Material Focus
Thermal Properties
0
50
100
150
200
250
300
350
PEEK PPSU PEI PPA PA66 PA12
Tg Tm HDT A HDT B
Tem
pera
tur
(°C
)
PEEK Material Properties
Key Properties:
• Excellent chemical, mechanical &
thermal resistance
• Low water absorption, dimension
stability & constant material properties
over a wide temperature & humidity
range
• Excellent sliding friction behavior,
minimal abrasion
• Outstanding chemical and hydrolysis
resistance
• Low tendency to form stress cracks and
low creep at high load
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CBAM Microstructure
CT Scan – courtesy of
Carbon Fiber/PEEK Tool
Standard void content ranges from 1 to 10%
PMC Microstructure
500X
100X
X Z
Baseline Material Properties
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Test standard Test standard measurement Carbon+ Nylon 12 Carbon+ PEEK
Mechanical Properties
ASTM D256 Notched Impact 7.1 KJ/m2 49.3 KJ/m2
ASTM D4812 Unnotched Impact 18.8 KJ/m2 13.2 KJ/m2
ASTM D638 Tensile 102.6 Mpa (14.8 ksi) 131.9 Mpa (19.1 ksi)
ASTM D638 E-modulus 9.22 Gpa (1337.4 ksi) 12.74 Gpa (1847.7 ksi)
ASTM D638 Poisson's ratio 0.44 0.32
ASTM D638 Elongation % 1.20 1.04
ASTM D695 Compression 7802 psi 23500 psi
ASTM D790 Ultimate Flexural Strength 131.5MPa (19.1 ksi) 176.7 MPa (25.6 kpsi)
ASTM D790 Flex modulus 9.05 Gpa (1312 ksi) 12.43 Gpa (1802 ksi)
Thermal Properties
ASTM D648 HDT 332°F (167°C) 315°C - 340°C
ASTM D5470 Thermal transmission 1mm with sic oil 4.01 K/W 5.39 K/W
ASTM D5470 Thermal conductivity transmission 1mm with sic oil 0.279 W/mk 0.223 W/mk
ASTM E831 CTE - below softening point 176.7 µm/m°C 65.5 µm/m°C
ASTM E831 CTE - above softening point 389.2 µm/m°C 246.9 µm/m°C
Thermal Properties
Density 1.1 g/cm3 1.4 g/cm3
Part Tolerance Analysis
Part Tolerance
Part surface finish & feature detail
• Great feature detail
• Parts can be post processed to a Surface finish Roughness Ra of 20 micro-inches (µin)
Light weight structures
• 50% lighter than aluminum part
• Enables integrated part designs
• Self aligning assembly features
• Capability to incorporate text into parts
• Improves product performance
Monolithic Structures
• Design freedom to combine multiple components
• Capability to build variable wall thicknesses
• Capability to make parts with various fine to large feature details
• Various build material options
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Enclosure Cases
EMI enclosure cases – Fiberglass/PA12 • Transparent to radio EMI/RFI transmissions • Non-conductive • High dielectric capability • Very light weight 1.1 g/cm3
Electronics Enclosures – Carbon/PEEK • Electrical Conductivity • High temperature resistance • Static dissipation • Chemical resistance • Very light weight 1.4 g/cm3
Multi-functional structures
Glass fiber layer
Carbon fiber layers
Non-conductive glass fiber layer
Conductive carbon fiber layers
• Upper and lower surface made with nonwoven carbon
• Sandwich structure is 17 gsm nonwoven fiberglass
• Nylon 12 thermoplastic as the matrix material
• Demonstrates conductive and insulative material properties
• Provides capability to tailor electrical and mechanical part properties
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Tooling Applications
• Drill guides
• High temperature tooling
• High temperature 350◦ F Composite fabrication tools
(ORNL CRADA)
• Metal forming
CBAM Model One Pilot System
• 12” x 8” min. up to 12” x 18” build envelope
• Print speeds of 6 -10 sheets/minute
• Robust electronics
Impossible Objects Confidential
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Thank you for your time.