A reconfigurable tool for vat photopolymerization of curved fiber reinforced composite parts

Purpose Manufacturing curved composite structures is a challenging process that requires expensive tooling. The purpose of this study is to introduce and demonstrate a new technology for manufacturing nonplanar (curved) glass fiber composite parts via a transparent, reconfigurable tool that couples with standard vat photopolymerization techniques. Design/methodology/approach This study demonstrates a new technology to manufacture nonplanar (curved) glass fiber composite parts using a transparent, reconfigurable tool mounted on a commercial vat photopolymerization 3D printer. The tool comprises small transparent rods actuated by pushing a printed neat resin mold against the tool to generate a curved surface. The resulting surface is locked in place, and a curved composite is then made by sandwiching a resin wetted fiber mat between the tool and the part, followed by applying pressure and ultraviolet light exposure. The tooling and printing processes are demonstrated using a commercial vat photopolymerization 3D printer. The technology’s performance and limitations are assessed through 3D profilometry and mechanical testing of printed parts. Findings The tool successfully produces various curved composite parts via a rapid and facile method. Mechanical testing shows that the printed parts have satisfactory performance, validating the method’s effectiveness. Originality/value This approach provides a simple, cost-effective way to prototype and replicate curved fiber-reinforced parts, eliminating the need for expensive tooling and advancing the field of composite manufacturing.