Nonplanar 3D Printing of Epoxy Using Freeform Reversible Embedding

Area of Science:

• Materials Science
• Polymer Science
• Additive Manufacturing

Background:

• Thermoset polymers like epoxies offer excellent thermal, chemical, and mechanical properties, making them valuable in various industries.
• Traditional 3D printing of thermosets is hindered by their flow during extrusion and long cure times, limiting structural complexity.
• Support baths can aid 3D printing by maintaining shape during curing, enabling more intricate designs.

Purpose of the Study:

• To investigate the use of Freeform Reversible Embedding (FRE) for 3D printing off-the-shelf thermoset epoxies.
• To explore the impact of extrusion direction on epoxy filament morphology and fusion in 3D space.
• To demonstrate the potential for creating advanced lattice structures with improved mechanical performance.

Main Methods:

• Utilized Freeform Reversible Embedding (FRE) to 3D print thermoset epoxy resins.
• Employed non-planar extrusion techniques within a support bath.
• Analyzed the influence of extrusion direction on filament characteristics and inter-filament bonding.

Main Results:

• Successfully 3D printed thermoset epoxy into complex lattice structures using FRE and non-planar extrusion.
• Demonstrated control over epoxy filament morphology and fusion through extrusion direction.
• Achieved lattice geometries with approximately four times greater specific modulus compared to existing methods.

Conclusions:

• FRE provides a viable method for 3D printing thermoset epoxies, overcoming challenges related to flow and cure time.
• Non-planar extrusion within FRE allows for the fabrication of high-performance lattice structures.
• This technique significantly advances the capabilities of additive manufacturing for thermoset materials.