RAPID CHARACTERIZATION OF ADDITIVELY MANUFACTURED CONTINUOUS FIBER COMPOSITE MATERIALS

Processes that additively deposit reactive resin infused fiber tows (ADRRIFT), such as Continuous Composites, Inc.’s CF3D® system, can provide high fiber volume fraction (FVF), low void volume fraction (VVF), and fiber dominated properties that approach traditional composites. Using a custom fiber placement system, called the ADRRIFT Test Bed, processing windows for new and uncertified material resins as a function of key printing variables such as print speed, nozzle size, compaction force, and curing condition can be assessed. In this study, we first investigate the dimensions and FVF of carbon fiber tows infused with PolyMat, a CF3D® certified resin, by both processes as a function of compaction force. We then investigate carbon fiber tows infused with a dicyclopentadiene (DCPD) derivatives containing 10 % dihydrofuran (DHF), an uncertified resin capable of frontal polymerization and deconstruction for composite recycling. This DCPD/DHF formulation with carbon fiber tows is studied as a function of applied compaction force and properties are compared with PolyMat, both on the Test Bed. We find that while the FVF and the area of the PolyMat/carbon fiber tows from the CF3D® system and the ADRRIFT Test Bed are nearly the same, the Test Bed produces ~16-20 % narrower and thicker deposited tows than the commercial system for similar compaction force.