3D-Printed Porous Structure and Polymer Infiltration for Fabrication of Functionally Gradient Material with Complex Shape

3D打印多孔结构和聚合物渗透用于制造复杂形状的功能梯度材料

• 批准号: 1522877
• 负责人: Li-Jung Tai
• 金额: $ 29.45万
• 依托单位: Texas A&M Engineering Experiment Station
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2015
• 资助国家: 美国
• 起止时间: 2015-01-01 至 2019-06-30
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1522877&HistoricalAwards=false
• 关键词: 3D; Printed; Porous; Structure; Polymer

Additive manufacturing includes a variety of 3D fabrication technologies. Starting from early powder-based 3D printing, commercial machines are now capable of producing thermoplastics using fused deposition modeling, ultraviolet curable polymers using stereolithography, and metals using laser sintering techniques. However, additive manufacturing of composites or bi-materials remains challenging, particularly for two materials with significantly different properties that can be combined in various ratios to create different mechanical behaviors. This research aims to develop a manufacturing method, in which 3D printing is utilized to make specific scaffold structures, allowing polymer to infiltrate and reinforce the part. This new method will enable development of functionally gradient materials, light-weight design, and reinforced structures for applications of additive manufacturing in rapid prototyping, healthcare, automotive and aerospace. Outcomes of this research will stimulate the next-generation additive manufacturing technology and provide education and research opportunities for students of many different backgrounds. This research focuses on understanding the infiltration mechanism of the polymer through certain parameters, such as viscosity and surface tension, and mechanical behaviors of the polymer infiltrated composite in order to customize material properties, including stiffness, hardness, strength, and isotropy or anisotropy. To this end, this research includes two tasks. First, the research team will study and simulate the infiltration phenomenon using computational fluid dynamics and validate with design of experiments. The results will define the structural limits to capsulate or drain liquid polymers prior to solidification. In the second task, they will investigate the rule of mixtures for composite mechanics under a variety of scaffold structures and the non-linear behavior of the composite under extreme loads. Results from this research can be used to establish a material decomposition algorithm. This algorithm can thus be used to define scaffold structure and polymer selection given a set of desired material properties.

添加剂制造包括各种3D制造技术。从早期粉末的3D打印开始，商用机器现在能够使用融合沉积建模，使用立体光刻的紫外线固化聚合物以及使用激光烧结技术来生产热塑性塑料。但是，复合材料或双材料的添加剂制造仍然具有挑战性，特别是对于两种具有明显不同特性的材料，可以以各种比率组合来创造不同的机械行为。这项研究旨在开发一种制造方法，其中3D打印被用来制造特定的脚手架结构，从而使聚合物渗入并加强了零件。这种新方法将能够开发功能梯度材料，轻量级设计以及用于在快速原型制造，医疗保健，汽车和航空航天中应用的增强结构。这项研究的结果将刺激下一代添加剂制造技术，并为许多不同背景的学生提供教育和研究机会。这项研究的重点是通过某些参数（例如粘度和表面张力）以及聚合物浸润复合材料的机械行为来理解聚合物的浸润机制，以自定义材料特性，包括刚度，硬度，强度和同型和各向异性或各向异性。为此，这项研究包括两个任务。首先，研究团队将使用计算流体动力学研究和模拟渗透现象，并通过设计实验验证。结果将定义结构限制，以在凝固之前倾斜或排出液体聚合物。在第二个任务中，他们将研究在多种脚手架结构下的复合力学混合物规则，以及在极端载荷下复合材料的非线性行为。这项研究的结果可用于建立材料分解算法。因此，该算法可用于定义脚手架结构和聚合物选择，并在一组所需的材料特性下进行选择。