Near-Isotropic, High-Strength, High-Stiffness Thermoset Composite 3D Printing for Drop-In Replacement of Machined Metals

A novel microstructural phenomenon in 3D printed polymer composites has been discovered, which yield unusually high strength and stiffness. This results in excellent properties not only in the primary print direction, but also transversely to the printed beads. This project will further quantify the properties of this process and evaluate the out-of-plane transverse properties. Based on the property data that exists now, it is possible to replace machined aluminum parts with a lighter alternative, especially in stiffness-driven applications. While the properties achievable are far lower than the state-of-the-art in high performance aerospace parts (Mantis Composites), they are high enough to provide an intermediate advantage over alloys.  Additionally, inherent multi-directional properties from 3-axis printing that will be validated will allow the process to provide an advantage as a drop-in replacement at a low cost, whereas traditional 3D printing often requires extensive re-design.