3D Printed Short-Fibre Thermosetting Resin Preform Infiltration
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Solution Overview
Problem
Current 3D printing technologies face challenges in manufacturing complex structures with high strength and heat resistance using thermosetting resin composites, particularly due to the difficulty in forming cantilever structures and the limitations of thermoplastic and UV curing resin methods, which result in products with low intensity and increased production costs.
Innovation Solution
A method involving the preparation of a composite powder with 10-50% polymer adhesive and 50-90% chopped fibers, followed by selective laser sintering to create a preform with porosity and high bending strength, and subsequent infiltration with a liquid thermosetting resin precursor, allowing for the formation of complex structures with enhanced mechanical properties and heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermoplastic resin powder and reinforced fiber powder are mixed and selective laser sintering is utilized, then complex structures can be manufactured, but the product intensity is low
Solution Approach 1:
The patent uses composite materials by combining thermosetting resin with reinforced fibers (carbon fiber, glass fiber, or aramid fiber) to create a composite powder mixture. This composite approach enables both complex structure manufacturing through 3D printing and high product intensity, resolving the contradiction between ease of manufacture and strength.
2Ease of manufacture
If composite wires or impregnating wire bunch is prepared and fused deposition technology is utilized, then manufacturing is possible, but it is difficult to form complex products possessing cantilever structures
Solution Approach 1:
The patent changes the material parameters by using thermosetting resin instead of thermoplastic resin, and controls the viscosity within a specific range (50-200 cP) to enable the formation of complex structures including cantilevers through selective laser sintering, thereby improving adaptability while maintaining manufacturing capability.
3Ease of manufacture
If reinforced fiber and UV curing resin are uniformly mixed and photocuring technology is utilized, then manufacturing is possible, but products have low intensity and production cost increases
Solution Approach 1:
The patent changes the curing mechanism from UV photocuring to thermal curing through selective laser sintering. By controlling the viscosity of thermosetting resin within 50-200 cP and using laser-induced thermal energy for curing, the method achieves both manufacturing capability and high product intensity while avoiding the cost and strength issues of UV curing methods.
4Ease of operation
If thermosetting resin is used with low viscosity, then extrusion through nozzle is possible, but the shape of the material is difficult to be kept
Solution Approach 1:
The patent replaces the mechanical extrusion system with a laser-based selective sintering system. Instead of extruding material through a nozzle, the laser directly sinters the thermosetting resin and fiber powder mixture layer by layer, enabling both low viscosity material handling and excellent shape retention through precise laser-controlled curing.
5Stability of the object's composition
If thermosetting resin is used with high viscosity, then shape retention is possible, but it is difficult to extrude the material out of a nozzle or heat and melt the material by the laser
Solution Approach 1:
The patent optimizes the viscosity parameter of thermosetting resin to a specific range (50-200 cP) that balances shape retention and processability. This parameter control enables both adequate shape retention and successful extrusion/laser melting, resolving the contradiction between stability and ease of manufacture.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the direct manufacturing of composite products with complex shapes, including cantilever structures, offering improved mechanical properties and heat resistance, while reducing production cycles and costs, and is applicable to various reinforced fibers and thermosetting resin systems.
Implementation Method 1
shaping the composite powder by using a selective laser sintering technology to yield a preform comprising pores
Implementation Method 2
directing a programmable planar light source to predetermined areas of the first layer to form a first cross-section
Implementation Method 3
allowing a liquid thermosetting resin of the liquid thermosetting resin precursor to infiltrate into the pores of the preform
Implementation Method 4
The thermosetting resin is a reactive resin and needs to be cured with a curing agent for several hours at a specific curing temperature and pressure (chemical cross-linking) to form a stable network crosslinking
Data Source
Figure 1
AI summary
Disclosed is a method for manufacturing a composite product made of a short-fiber reinforced thermosetting resin by means of 3D printing. The method comprises the following steps: 1) preparing composite powder suitable for a 3D printing technology using selective laser sintering ; 2) forming a preform with pores by using a selective laser sintering technology; 3) performing post-infiltration treatment on the preform in a liquid thermosetting resin precursor: 3.1) preparing a liquid thermosetting resin precursor with a viscosity of 100 mPa.s or lower, and 3.2) infiltrating the preform into the liquid thermosetting resin precursor, exposing the upper end surface of the preform from the liquid level, thereby discharging gas in the pores of the preform; 4) taking out the preform from the liquid thermosetting resin precursor, and curing the preform after removing excess resin; and 5) polishing the cured preform to obtain a finished product. The present invention can achieve rapid manufacture of a composite product made of a fiber reinforced thermosetting resin that has a complex structure, low weight, high strength and high heat resistance.