3D Printing Continuous Carbon Fiber Reinforced Epoxy via In-situ Nanocomposite Microwave Curing

Raven 3D, the University of Oklahoma (OU), Gerling Consulting, Inc. (GCI), and Güdel Inc. propose to develop FiberQuill, a scalable Direct Ink Writing (DIW) 3D printing method capable of printing epoxy coated continuous carbon fiber (e-CCF) to fabricate extraordinarily high strength-to-weight ratio aircraft parts. In the Phase I effort, the team will develop the FiberQuill printhead that uses microwave energy to cure the extruded e-CCF immediately after deposition to enable continuous carbon fiber (CCF) DIW for the needs of the Air Force. For Phase II and beyond, the 3D printing technique can be scaled-up to larger build volumes utilizing robotic manufacturing systems provided by Güdel. FiberQuill will enable 3D printing of large carbon fiber composite structures with comparable mechanical and thermal properties to composite laminates. This technology will allow the Air Force and the aerospace industry to manufacture optimally designed composite aircraft components that were previously unable to be fabricated via molding. FiberQuill will improve the performance, reduce the number of parts, and simplify maintenance for cutting edge composite aircraft.