I-Corps: 3D Printing of carbon fiber reinforced polymer on contoured surfaces

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The broader impact/commercial potential of this I-Corps project will derive from a new 3D printing technology that can address critical needs in small volume/smart devices by providing products with increased strength-to-weight ratios, integrated materials that enable designed functionality, and a high degree of feature customization. 3D printed components with optimal shape and functional properties have a multitude of potential applications in the automotive, aerospace, environmental monitoring and medical fields. With the potential introduction of commercial drone applications, this technology will meet an increased need for flexible payload carrier fabrication techniques that can be customized for payload specific weight, strength, and design requirements. Additionally, the technology described in this project will provide an alternative fabrication approach for customized assistive devices that has the potential to decrease production time, lower waste and energy consumption, decrease costs, improve assistive device customization and user performance. Lastly, the ability to embed novel capabilities such as monitoring acceleration or temperature and pressure at the skin interface into these devices aligns with a growing societal interest in wearable sensors.This I-Corps project will identify the key value propositions of a novel 3D printing technology for targeted customers and quantify the market value for devices fabricated with this technology across several application areas. Key strategic partners and major competitors within the general areas that align with this technology will be investigated. The intellectual merit of this project lies in the new knowledge that will be obtained regarding application driven needs for 3D printing of fiber reinforced polymers that enable customized fabrication of smart, functional devices. This advanced 3D printing technology reconfigures and extends the functionality of a fused deposition modeling (FDM) 3D printing approach to enable 3D printing of continuous fiber composite materials along curvatures on multiple planes, including overhanging features. Preliminary results from this technology have demonstrated the first example of out-of-plane 3D printing at the meso-scale. The new knowledge resulting from this I-Corps project will inform and direct further technological advancements towards the development of a printing system targeted for specific application needs in size, strength, resolution, and material diversity.