Molds with Advanced Materials for Carbon Fiber Manufacturing with 3D Printing Technology
Fused Deposition Modeling (FDM) 3D printing is the most widespread technology in additive manufacturing worldwide that thanks to its low costs, finished component applications, and the production process of other parts. The need for lighter and higher-performance components has led to an increased u...
| Main Authors: | , , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2021-10-01
|
| Series: | Polymers |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2073-4360/13/21/3700 |
| _version_ | 1797511955256180736 |
|---|---|
| author | Patrich Ferretti Gian Maria Santi Christian Leon-Cardenas Marco Freddi Giampiero Donnici Leonardo Frizziero Alfredo Liverani |
| author_facet | Patrich Ferretti Gian Maria Santi Christian Leon-Cardenas Marco Freddi Giampiero Donnici Leonardo Frizziero Alfredo Liverani |
| author_sort | Patrich Ferretti |
| collection | DOAJ |
| description | Fused Deposition Modeling (FDM) 3D printing is the most widespread technology in additive manufacturing worldwide that thanks to its low costs, finished component applications, and the production process of other parts. The need for lighter and higher-performance components has led to an increased usage of polymeric matrix composites in many fields ranging from automotive to aerospace. The molds used to manufacture these components are made with different technologies, depending on the number of pieces to be made. Usually, they are fiberglass molds with a thin layer of gelcoat to lower the surface roughness and obtain a smooth final surface of the component. Alternatively, they are made from metal, thus making a single carbon fiber prototype very expensive due to the mold build. Making the mold using FDM technology can be a smart solution to reduce costs, but due to the layer deposition process, the roughness is quite high. The surface can be improved by reducing the layer height, but it is still not possible to reach the same degree of surface finish of metallic or gelcoat molds without the use of fillers. Thermoplastic polymers, also used in the FDM process, are generally soluble in specific solvents. This aspect can be exploited to perform chemical smoothing of the external surface of a component. The combination of FDM and chemical smoothing can be a solution to produce low-cost molds with a very good surface finish. |
| first_indexed | 2024-03-10T05:55:16Z |
| format | Article |
| id | doaj.art-d3fc75b21a6946a693ec1ebe8e268af6 |
| institution | Directory Open Access Journal |
| issn | 2073-4360 |
| language | English |
| last_indexed | 2024-03-10T05:55:16Z |
| publishDate | 2021-10-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Polymers |
| spelling | doaj.art-d3fc75b21a6946a693ec1ebe8e268af62023-11-22T21:27:35ZengMDPI AGPolymers2073-43602021-10-011321370010.3390/polym13213700Molds with Advanced Materials for Carbon Fiber Manufacturing with 3D Printing TechnologyPatrich Ferretti0Gian Maria Santi1Christian Leon-Cardenas2Marco Freddi3Giampiero Donnici4Leonardo Frizziero5Alfredo Liverani6Department of Industrial Engineering, Alma Mater Studiorum University of Bologna, I-40136 Bologna, ItalyDepartment of Industrial Engineering, Alma Mater Studiorum University of Bologna, I-40136 Bologna, ItalyDepartment of Industrial Engineering, Alma Mater Studiorum University of Bologna, I-40136 Bologna, ItalyDepartment of Industrial Engineering, Alma Mater Studiorum University of Bologna, I-40136 Bologna, ItalyDepartment of Industrial Engineering, Alma Mater Studiorum University of Bologna, I-40136 Bologna, ItalyDepartment of Industrial Engineering, Alma Mater Studiorum University of Bologna, I-40136 Bologna, ItalyDepartment of Industrial Engineering, Alma Mater Studiorum University of Bologna, I-40136 Bologna, ItalyFused Deposition Modeling (FDM) 3D printing is the most widespread technology in additive manufacturing worldwide that thanks to its low costs, finished component applications, and the production process of other parts. The need for lighter and higher-performance components has led to an increased usage of polymeric matrix composites in many fields ranging from automotive to aerospace. The molds used to manufacture these components are made with different technologies, depending on the number of pieces to be made. Usually, they are fiberglass molds with a thin layer of gelcoat to lower the surface roughness and obtain a smooth final surface of the component. Alternatively, they are made from metal, thus making a single carbon fiber prototype very expensive due to the mold build. Making the mold using FDM technology can be a smart solution to reduce costs, but due to the layer deposition process, the roughness is quite high. The surface can be improved by reducing the layer height, but it is still not possible to reach the same degree of surface finish of metallic or gelcoat molds without the use of fillers. Thermoplastic polymers, also used in the FDM process, are generally soluble in specific solvents. This aspect can be exploited to perform chemical smoothing of the external surface of a component. The combination of FDM and chemical smoothing can be a solution to produce low-cost molds with a very good surface finish.https://www.mdpi.com/2073-4360/13/21/3700FDMchemical smoothingvapor smoothingPVBcarbon fiber mold |
| spellingShingle | Patrich Ferretti Gian Maria Santi Christian Leon-Cardenas Marco Freddi Giampiero Donnici Leonardo Frizziero Alfredo Liverani Molds with Advanced Materials for Carbon Fiber Manufacturing with 3D Printing Technology Polymers FDM chemical smoothing vapor smoothing PVB carbon fiber mold |
| title | Molds with Advanced Materials for Carbon Fiber Manufacturing with 3D Printing Technology |
| title_full | Molds with Advanced Materials for Carbon Fiber Manufacturing with 3D Printing Technology |
| title_fullStr | Molds with Advanced Materials for Carbon Fiber Manufacturing with 3D Printing Technology |
| title_full_unstemmed | Molds with Advanced Materials for Carbon Fiber Manufacturing with 3D Printing Technology |
| title_short | Molds with Advanced Materials for Carbon Fiber Manufacturing with 3D Printing Technology |
| title_sort | molds with advanced materials for carbon fiber manufacturing with 3d printing technology |
| topic | FDM chemical smoothing vapor smoothing PVB carbon fiber mold |
| url | https://www.mdpi.com/2073-4360/13/21/3700 |
| work_keys_str_mv | AT patrichferretti moldswithadvancedmaterialsforcarbonfibermanufacturingwith3dprintingtechnology AT gianmariasanti moldswithadvancedmaterialsforcarbonfibermanufacturingwith3dprintingtechnology AT christianleoncardenas moldswithadvancedmaterialsforcarbonfibermanufacturingwith3dprintingtechnology AT marcofreddi moldswithadvancedmaterialsforcarbonfibermanufacturingwith3dprintingtechnology AT giampierodonnici moldswithadvancedmaterialsforcarbonfibermanufacturingwith3dprintingtechnology AT leonardofrizziero moldswithadvancedmaterialsforcarbonfibermanufacturingwith3dprintingtechnology AT alfredoliverani moldswithadvancedmaterialsforcarbonfibermanufacturingwith3dprintingtechnology |