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Abstract Thermoset composites, utilized in additive manufacturing, are distinguished by their excellent thermal and mechanical properties, enabling them to maintain structural integrity even under high-temperature conditions. An accurate method for characterizing the mechanical properties is necessary to ensure the performance parameters, reliability, and safety of materials during and post-manufacturing. However, characterizing 3D-printed thermoset composites is challenging due to the anisotropy introduced by the additive manufacturing process and factors such as delamination and porosity. This also leads to difficulties in accurately characterizing composites with traditional testing methods. To address this, this paper introduces a novel method that combines a non-destructive Piezoelectric transducer-laser Doppler Vibrometer (PZT-LDV) guided wave sensing system with an optimization algorithm-enhanced wavenumber analysis technique. A series of experiments were conducted to validate the concept of measuring the mechanical properties of a 3D-printed thermoset material panel. Our method successfully determined two material properties — shear wave speed and Poisson’s ratio in multiple directions on the test panel. This study aims to establish a precise and rapid non-destructive testing method that can effectively characterize various composite materials and monitor their performance throughout the additive manufacturing process. 

Abstract Thermoset materials have begun to be applied in additive composite manufacturing due to their ability to withstand high temperatures without losing structural integrity. Meanwhile, the characterization of mechanical properties for additively manufactured composites is critical for ensuring material reliability and safety. However, traditional testing methods struggle to accurately and nondestructively characterize additively manufactured composites due to challenges posed by curing processes, microstructural variability, anisotropic properties of thermoset composites, and the risk of damaging these materials during evaluation. For characterizing the mechanical properties of additive-manufactured thermoset composites, this paper presents a novel method that combines a nondestructive PZT-LDV guided wave sensing system and a wavenumber analysis that fuses multidimensional Fourier transform with dispersion curve regression. For proof of concept, we performed an experiment using our method to measure a 3D-printed thermoset composite panel. Based on our nondestructive approach, two material properties (shear wave velocity and Poisson’s ratio) in multiple directions were successfully determined for the tested panel. We expect this research to introduce a non-contact and efficient method for characterizing various composites and monitoring their property changes after additive manufacturing.