The utilization of multifunctional composite materials presents significant advantages in terms of system efficiency, cost-effectiveness, and miniaturization, making them highly valuable for a wide range of industrial applications. One approach to harness the multifunctionality of carbon fiber reinforced polymer (CFRP) is to integrate it with a secondary material to form a hybrid composite. In our previous research, we explored the use of carbonaceous material derived from coconut shells as a sustainable alternative to inorganic fillers, aiming to enhance the out-of-plane mechanical performance of CFRP. In this study, our focus is to investigate the influence of carbonized coconut shell particles on the non-structural properties of CFRP, specifically electromagnetic interference (EMI) shielding, thermal stability, and water absorption resistance. The carbonized material was prepared by thermal processing at 400 °C. Varying proportions of carbonized material, ranging from 1% to 5% by weight, were thoroughly mixed with epoxy resin to form the matrix used for impregnating woven carbon fabric with a volume fraction of 29%. Through measurements of scattering parameters, we found that the hybrid composites with particle loadings up to 3% exhibited EMI shielding effectiveness suitable for industrial applications. Also, incorporating low concentrations of carbonized particle to CFRP enhances the thermal stability of hybrid CFRP composites. However, the inclusion of carbonized particle to CFRP has a complex effect on the glass transition temperature. Even so, the hybrid composite with 2% particle loading exhibits the highest glass transition temperature and lowest damping factor among the tested variations. Furthermore, when subjected to a 7-day water immersion test, hybrid composites with 3% or less amount of carbonized particle showed the least water absorption. The favorable outcome can be attributed to good interfacial bonding at the matrix/fiber interface. Conversely, at higher particle concentrations, aggregation of particles and formation of interfacial and internal pores was observed, ultimately resulting in deteriorated measured properties. The improved non-structural functionalities observed in these biocomposites suggest the potential for a more sustainable and cost-effective alternative to their inorganic-based counterparts. This advancement in multifunctional composites could pave the way for enhanced applications of biocomposites in various industries.
WOVEN NATURAL FIBER-REINFORCED PLA POLYMERS 3D PRINTED THROUGH A LAMINATED OBJECT MANUFACTURING PROCESS
A novel additive manufacturing process utilizing the laminated object manufacturing (LOM) technology with woven natural fiber-reinforced biopolymer is investigated in this paper. Traditional synthetic composite materials are products from nonrenewable crude oil with limited end-of-life options, and therefore not environmentally friendly. The continuous woven natural fiber is used to significantly strengthen the mechanical properties of biocomposites and PLA biopolymer as the matrix made the material completely biodegradable. This is one of the promising replacements for synthetic composites in applications such as automotive panels, constructive materials, and sports and musical instruments. A LOM 3D printer prototype has been designed and built by the team using a laser beam in cutting the woven natural fiber reinforcement and molten PLA powder to bind layers together. Tensile and flexural properties of the LOM 3D printed biocomposites were measured using ASTM test standards and then compared with corresponding values measured from pure PLA specimens 3D printed through FDM. Improved mechanical properties from LOM 3D-printed biocomposites were identified by the team. SEM imaging was performed to identify the polymer infusing and fiber-matrix binding situations. This research took advantage of both the material and process’s benefits and combine them into one sustainable practice.
more »
« less
- Award ID(s):
- 1900699
- NSF-PAR ID:
- 10417572
- Editor(s):
- Beckwith, S.; Flinn, B.; Dustin, J.
- Date Published:
- Journal Name:
- SAMPE 2023 Proceedings
- Page Range / eLocation ID:
- TP23-0000000198
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
More Like this
-
more » « less
-
null (Ed.)Purpose This paper aims to summarize the up-to-date research performed on combinations of various biofibers and resin systems used in different three-dimensional (3D) printing technologies, including powder-based, material extrusion, solid-sheet and liquid-based systems. Detailed information about each process, including materials used and process design, are described, with the resultant products’ mechanical properties compared with those of 3D-printed parts produced from pure resin or different material combinations. In most processes introduced in this paper, biofibers are beneficial in improving the mechanical properties of 3D-printed parts and the biodegradability of the parts made using these green materials is also greatly improved. However, research on 3D printing of biofiber-reinforced composites is still far from complete, and there are still many further studies and research areas that could be explored in the future. Design/methodology/approach The paper starts with an overview of the current scenario of the composite manufacturing industry and then the problems of advanced composite materials are pointed out, followed by an introduction of biocomposites. The main body of the paper covers literature reviews of recently emerged 3D printing technologies that were applied to biofiber-reinforced composite materials. This part is classified into subsections based on the form of the starting materials used in the 3D printing process. A comprehensive conclusion is drawn at the end of the paper summarizing the findings by the authors. Findings Most of the biofiber-reinforced 3D-printed products exhibited improved mechanical properties than products printed using pure resin, indicating that biofibers are good replacements for synthetic ones. However, synthetic fibers are far from being completely replaced by biofibers due to several of their disadvantages including higher moisture absorbance, lower thermal stability and mechanical properties. Many studies are being performed to solve these problems, yet there are still some 3D printing technologies in which research concerning biofiber-reinforced composite parts is quite limited. This paper unveils potential research directions that would further develop 3D printing in a sustainable manner. Originality/value This paper is a summary of attempts to use biofibers as reinforcements together with different resin systems as the starting material for 3D printing processes, and most of the currently available 3D printing techniques are included herein. All of these attempts are solutions to some principal problems with current 3D printing processes such as the limit in the variety of materials and the poor mechanical performance of 3D printed parts. Various types of biofibers are involved in these studies. This paper unveils potential research directions that would further widen the use of biofibers in 3D printing in a sustainable manner.more » « less
-
Ozden Ochoa (Ed.)This paper investigates the mechanical properties of potential sheet stocks of a Laminated Object Manufacturing (LOM) 3D printer made using woven jute fabrics infused with two types of bioresin. The combinations of bioresins and the reinforcements would make green sheet stocks that are expected to be environmentally friendly comparing to traditional synthetic fibers infused with regular resins. Pure resin samples are also involved for comparison purposes. Both tensile and flexural properties are measured following ASTM D638 and D3039 standards (for tensile tests) as well as ASTM D790 and D7264 standards (for flexural tests). Detailed processes of specimen preparation followed by test procedures are introduced. Tensile strengths and moduli as well as flexural strengths and moduli are obtained for comparison. Based on the study of the mechanical properties of both types of pure resin and woven jute fiber-reinforced composites, the research team concluded a few important findings that could be used as guidelines in the sheet stock selection and preparation for the LOM 3D printer that is currently under the building process.more » « less
-
Additive manufacturing promises to revolutionize manufacturing industries. However, 3D printing of novel build materials is currently limited by constraints inherent to printer designs. In this work, a bench-top powder melt extrusion (PME) 3D printer head was designed and fabricated to print parts directly from powder-based materials rather than filament. The final design of the PME printer head evolved from the Rich Rap Universal Pellet Extruder (RRUPE) design and was realized through an iterative approach. The PME printer was made possible by modifications to the funnel shape, pressure applied to the extrudate by the auger, and hot end structure. Through comparison of parts printed with the PME printer with those from a commercially available fused filament fabrication (FFF) 3D printer using common thermoplastics poly(lactide) (PLA), high impact poly(styrene) (HIPS), and acrylonitrile butadiene styrene (ABS) powders (< 1 mm in diameter), evaluation of the printer performance was performed. For each build material, the PME printed objects show comparable viscoelastic properties by dynamic mechanical analysis (DMA) to those of the FFF objects. However, due to a significant difference in printer resolution between PME (X–Y resolution of 0.8 mm and a Z-layer height calibrated to 0.1 mm) and FFF (X–Y resolution of 0.4 mm and a Z-layer height of 0.18 mm), as well as, an inherently more inconsistent feed of build material for PME than FFF, the resulting print quality, determined by a dimensional analysis and surface roughness comparisons, of the PME printed objects was lower than that of the FFF printed parts based on the print layer uniformity and structure. Further, due to the poorer print resolution and inherent inconsistent build material feed of the PME, the bulk tensile strength and Young’s moduli of the objects printed by PME were lower and more inconsistent (49.2 ± 10.7 MPa and 1620 ± 375 MPa, respectively) than those of FFF printed objects (57.7 ± 2.31 MPa and 2160 ± 179 MPa, respectively). Nevertheless, PME print methods promise an opportunity to provide a platform on which it is possible to rapidly prototype a myriad of thermoplastic materials for 3D printing.more » « less
-
more » « less
Abstract Engineered composite scaffolds composed of natural and synthetic polymers exhibit cooperation at the molecular level that closely mimics tissue extracellular matrix's (ECM) physical and chemical characteristics. However, due to the lack of smooth intermix capability of natural and synthetic materials in the solution phase, bio‐inspired composite material development has been quite challenged. In this research, we introduced new bio‐inspired material blending techniques to fabricate nanofibrous composite scaffolds of chitin nanofibrils (CNF), a natural hydrophilic biomaterial and poly (ɛ‐caprolactone) (PCL), a synthetic hydrophobic‐biopolymer. CNF was first prepared by acid hydrolysis technique and dispersed in trifluoroethanol (TFE); and second, PCL was dissolved in TFE and mixed with the chitin solution in different ratios. Electrospinning and spin‐coating technology were used to form nanofibrous mesh and films, respectively. Physicochemical properties, such as mechanical strength, and cellular compatibility, and structural parameters, such as morphology, and crystallinity, were determined. Toward the potential use of this composite materials as a support membrane in blood–brain barrier application (BBB), human umbilical vein endothelial cells (HUVECs) were cultured, and transendothelial electrical resistance (TEER) was measured. Experimental results of the composite materials with PCL/CNF ratios from 100/00 to 25/75 showed good uniformity in fiber morphology and suitable mechanical properties. They retained the excellent ECM‐like properties that mimic synthetic‐bio‐interface that has potential application in biomedical fields, particularly tissue engineering and BBB applications.
- Free Publicly Accessible Full Text
-
Accepted Manuscript1.0
- Conference Paper:
- https://doi.org/10.33599/nasampe/s.23.0198
