DLP-based additive manufacturing of hollow 3D structures with surface activated silicone carbide-polymer composite

IF 12.7 1区材料科学 Q1 ENGINEERING, MULTIDISCIPLINARY

Composites Part B: Engineering Pub Date : 2025-02-07 DOI:10.1016/j.compositesb.2025.112236

Anasheh Khecho, M.M Towfiqur Rahman, Deepshika Reddy, Ahmed El-Ghannam, Erina Baynojir Joyee

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引用次数: 0

Abstract

Additive manufacturing (AM) has revolutionized the fabrication of ceramic (Silicon Carbide, SiC)-polymer composites, offering enhanced material properties such as lighter weight, toughness, and thermal characteristics. Despite these advancements, a significant knowledge gap persists in effectively processing SiC with high solid loading to achieve desired mechanical and thermal behaviors. This paper addresses this gap by exploring material properties and addressing two major challenges: adequate rheology and avoiding printing failure for excessive separation force in photopolymerization-based AM processes.

In this study, high solid loading SiC-polymer composite resins were successfully developed for direct light projection (DLP)-based AM. Resin processability was determined by rheological properties and curing parameters, with resin preparation involving orthogonal optimization of compositions to achieve suitable viscosity, stability, and homogeneity. Experimental determination of photocuring parameters (curing time and critical exposure) was also conducted. Viscosity was found to increase with particle size reduction, with higher solid loading resulting in exponential viscosity growth. Additionally, a 3D part with a hollow structure and fine resolution, featuring densified uniform particle distribution, was successfully fabricated.

This study further developed a DLP prototype and SiC-polymer composites with varied particle size and loading concentrations were additively manufactured. The influence of SiC particles on compressive strength and thermal conductivity of the 3D printed samples was investigated. Results revealed a proportional relationship between compressive strength, thermal conductivity, and solid loading, demonstrating significant improvements compared to pure polymer matrices. This study provides a material basis for polymerization-based 3D printing of porous structures, demonstrating the potential for advanced applications in various industries.

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来源期刊

Composites Part B: Engineering 工程技术-材料科学：复合

CiteScore

24.40

自引率

11.50%

发文量

784

审稿时长

21 days

期刊介绍： Composites Part B: Engineering is a journal that publishes impactful research of high quality on composite materials. This research is supported by fundamental mechanics and materials science and engineering approaches. The targeted research can cover a wide range of length scales, ranging from nano to micro and meso, and even to the full product and structure level. The journal specifically focuses on engineering applications that involve high performance composites. These applications can range from low volume and high cost to high volume and low cost composite development. The main goal of the journal is to provide a platform for the prompt publication of original and high quality research. The emphasis is on design, development, modeling, validation, and manufacturing of engineering details and concepts. The journal welcomes both basic research papers and proposals for review articles. Authors are encouraged to address challenges across various application areas. These areas include, but are not limited to, aerospace, automotive, and other surface transportation. The journal also covers energy-related applications, with a focus on renewable energy. Other application areas include infrastructure, off-shore and maritime projects, health care technology, and recreational products.