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View article: A Novel Manufacturing Process of Lightweight Automotive Seats: Integration of Additive Manufacturing and Reinforced Polymer Composite
A Novel Manufacturing Process of Lightweight Automotive Seats: Integration of Additive Manufacturing and Reinforced Polymer Composite Open
View article: Additive Manufacturing of Self‐Sensing Carbon Fiber Composites
Additive Manufacturing of Self‐Sensing Carbon Fiber Composites Open
View article: Strength and thermal shock resistance of porous reaction-bonded silicon nitride by direct nitriding of binder jet additively manufactured silicon
Strength and thermal shock resistance of porous reaction-bonded silicon nitride by direct nitriding of binder jet additively manufactured silicon Open
The direct nitridation of binder jet additively manufactured silicon to produce porous silicon nitride was explored. The Taguchi Design of Experiments method was used to systematically study the effect of time, temperature, and nitrogen fl…
View article: The Cost of Scaling Up in Large-Format Additive Manufacturing
The Cost of Scaling Up in Large-Format Additive Manufacturing Open
Additive manufacturing (AM) of large objects has, over the last decade, required the scaling of existing material extrusion processes. The current generation of large-scale printers are primarily gantry robots with high-throughput extrusio…
View article: Optimizing Processing Conditions for Additively Reinforced Thermoforming (ART) in Convergent Manufacturing
Optimizing Processing Conditions for Additively Reinforced Thermoforming (ART) in Convergent Manufacturing Open
View article: Vacuum-assisted extrusion to reduce internal porosity in large-format additive manufacturing
Vacuum-assisted extrusion to reduce internal porosity in large-format additive manufacturing Open
View article: Innovative Joining Method for Hybrid Composites with Tailored Performance
Innovative Joining Method for Hybrid Composites with Tailored Performance Open
In various industries, such as renewables and aerospace, the demand for carbon fiber is rapidly growing to meet the requirements of high-performance applications with optimized designs. Traditionally, these optimized designs have been limi…
View article: Large-scale additive manufacturing with reactive polymers
Large-scale additive manufacturing with reactive polymers Open
The focus on large-scale polymer Additive Manufacturing (AM) has previously been on thermoplastic materials. However, Magnum Venus Products (MVP) along with researchers at Oak Ridge National Laboratory’s (ORNL) Manufacturing Demonstration …
View article: Graded Infill Structure of Wind Turbine Blade Accounting for Internal Stress in Big Area Additive Manufacturing
Graded Infill Structure of Wind Turbine Blade Accounting for Internal Stress in Big Area Additive Manufacturing Open
In additively manufactured (AM) components, infill structure significantly affects the mechanical performance of the final printed part. However, mechanical stress induced by operation loads has been so far neglected for infill patterning.…
View article: Design optimization of lightweight automotive seatback through additive manufacturing compression overmolding of metal polymer composites
Design optimization of lightweight automotive seatback through additive manufacturing compression overmolding of metal polymer composites Open
View article: Recent and future developments in pultrusion technology with consideration for curved geometries: A review
Recent and future developments in pultrusion technology with consideration for curved geometries: A review Open
View article: Experimental Investigation of Short Fiber Reinforced Thermoplastic Composite Joining in an Integrated Additive Manufacturing and Compression Molding System
Experimental Investigation of Short Fiber Reinforced Thermoplastic Composite Joining in an Integrated Additive Manufacturing and Compression Molding System Open
Fiber-reinforced thermoplastic (FRTP) composites have gained popularity within the aerospace and automotive industries due to their high specific strength-to-weight ratio compared to their metallic counterparts. State-of-the-art composite …
View article: In-Process Monitoring and Structural Health Monitoring of Large-Scale Additive Manufacturing Using Acoustic Emission Technique
In-Process Monitoring and Structural Health Monitoring of Large-Scale Additive Manufacturing Using Acoustic Emission Technique Open
ORNL collaborated with MISTRAS Group, Inc. to investigate acoustic emission (AE) as a structural health monitoring (SHM) method for large-scale additive manufacturing (AM). Large-scale AM is being adapted as method of producing large struc…
View article: Rheological Characteristics of Fiber Reinforced Poly(Ether Ketone Ketone) (PEKK) for Melt Extrusion Additive Manufacturing
Rheological Characteristics of Fiber Reinforced Poly(Ether Ketone Ketone) (PEKK) for Melt Extrusion Additive Manufacturing Open
Several grades of unreinforced and short fiber reinforced poly(ether ketone ketone) (PEKK) copolymers are analyzed for their potential use as feedstock materials in melt extrusion-based additive manufacturing (AM) systems. Rheological char…
View article: Parametric Analysis on Vertical Pins for Strengthening Extrusion-Based Printed Parts
Parametric Analysis on Vertical Pins for Strengthening Extrusion-Based Printed Parts Open
For extrusion-based additive manufacturing, the mechanical performance in vertical direction (z-direction) is significantly lower than that in the printed layer plane (xy-direction). This paper presents a vertical extrusion approach across…
View article: Effects of Mechanical Recycling on Carbon Fiber-Based Hybrid Composites
Effects of Mechanical Recycling on Carbon Fiber-Based Hybrid Composites Open
Carbon fiber (CF) reinforced composites are high-performing, highly utilized material systems historically used in aerospace. As the cost of CF decreases, other industries, such as automotive and energy generation, seek to adopt CF composi…
View article: Additive Manufacturing of Dissolvable Mandrels
Additive Manufacturing of Dissolvable Mandrels Open
ORNL collaborated with Mitsubishi Chemical America to investigate different grades of vinyl alcohol co-polymers as a potential feedstock material for large-scale material extrusion additive manufacturing (AM). Dissolvable polymers and can …
View article: System and method for simulation-assisted additive manufacturing involving estimating anisotropic deformation
System and method for simulation-assisted additive manufacturing involving estimating anisotropic deformation Open
A simulation-assisted additive manufacturing system and method for generating an anisotropic compensation to account for non-uniform deformation due to additive manufacturing and service loading. The predicted deformation may not be fully …
View article: Evaluation of Dissolvable Additively Manufactured Molds and Supports for Electroimpacts Innovative Additive Manufacturing Process
Evaluation of Dissolvable Additively Manufactured Molds and Supports for Electroimpacts Innovative Additive Manufacturing Process Open
Electroimpact inc. has developed a new additive manufacturing process involving continuous fiber reinforcement along with high-strength thermoplastics. A unique part of this process includes using additive manufacturing to print a base geo…
View article: Rheological evaluation of high temperature polymers to identify successful extrusion parameters
Rheological evaluation of high temperature polymers to identify successful extrusion parameters Open
With the advancements in additive manufacturing (AM), several high temperature thermoplastics are being explored as potential AM feedstocks. Some of these high-performance thermoplastics include; polyetherimides (PEI), polyphenylsulfones (…
View article: Reducing mechanical anisotropy in extrusion-based printed parts
Reducing mechanical anisotropy in extrusion-based printed parts Open
The mechanical performance of 3D printed components is highly dependent upon the orientation of the part relative to the build plane. Specifically for extrusion-based printing systems, the bond between successive layers (z-direction) can b…
View article: A VISCOELASTIC MODEL FOR EVALUATING EXTRUSION-BASED PRINT CONDITIONS
A VISCOELASTIC MODEL FOR EVALUATING EXTRUSION-BASED PRINT CONDITIONS Open
Extrusion-based printing systems have improved significantly over the past several years, allowing for higher throughput, higher temperatures, and larger components. At the same time, advanced materials are being introduced on the market t…
View article: Z-Pinning Approach for Reducing Mechanical Anisotropy of 3D Printed Parts
Z-Pinning Approach for Reducing Mechanical Anisotropy of 3D Printed Parts Open
The mechanical strength of extrusion-based printed parts is often greatly reduced (25-50%) in the build direction (z-direction) compared to the in-plane strength due to poor bonding between successively deposited layers. This effect can be…
View article: Characterization of anisotropic mechanical properties of polymer composites from a hybrid additive manufacturing-compression molding process using x-ray computer tomography
Characterization of anisotropic mechanical properties of polymer composites from a hybrid additive manufacturing-compression molding process using x-ray computer tomography Open
In this study, anisotropic stiffness tensors were reconstructed based on fiber orientation distributions obtained from X-ray computer tomography (xCT). A preform was manufactured via a big area additive manufacturing (BAAM) system with car…
View article: Systems and methods for generating a molecular dynamic graded lattice structure and their application to additive manufacturing
Systems and methods for generating a molecular dynamic graded lattice structure and their application to additive manufacturing Open
Systems and methods for generating molecular dynamic graded lattice structures that can be used as infill for additively manufactured articles. Molecular dynamically generated lattice infill is based on force balancing a node distribution …
View article: Development of multifunctional nylon 6,6-based nanocomposites with high electrical and thermal conductivities by scalable melt and dry blending methods for automotive applications
Development of multifunctional nylon 6,6-based nanocomposites with high electrical and thermal conductivities by scalable melt and dry blending methods for automotive applications Open
View article: Penetrating and actuating nozzle for extrusion-based 3D printing
Penetrating and actuating nozzle for extrusion-based 3D printing Open
An apparatus and device for creating a vertical strengthening feature within a 3D printed article of manufacture for improving mechanical performance in the Z-direction. Fill material is deposited in voids vertically crossing multiple laye…
View article: 3D PRINTED LAYER OF POLYANILINE-BASED CONDUCTIVE POLYMER FOR LIGHTNING STRIKE PROTECTION OF CFRPS
3D PRINTED LAYER OF POLYANILINE-BASED CONDUCTIVE POLYMER FOR LIGHTNING STRIKE PROTECTION OF CFRPS Open
Manufacturing of Carbon Fiber Reinforced Plastics (CFRPs) using additive manufacturing (AM), or 3D printing, has gained popularity in recent years. It is believed that the AM industry has the potential to manufacture CFRP parts in a faster…
View article: MICRO-CELLULOSE FIBER REINFORCED BIOCOMPOSITES FOR ADDITIVE MANUFACTURING
MICRO-CELLULOSE FIBER REINFORCED BIOCOMPOSITES FOR ADDITIVE MANUFACTURING Open
Polymer additive manufacturing (AM) technology is rapidly growing and it is transitioning from being primarily a prototyping method to an advanced manufacturing technique. Melt extrusion/fused deposition modeling, a method in which molten …
View article: An Integrated Design Approach for Infill Patterning of Fused Deposition Modeling and its Application to an Airfoil
An Integrated Design Approach for Infill Patterning of Fused Deposition Modeling and its Application to an Airfoil Open
We present a new approach to incorporate an internal stress distribution into the design of infill via fused deposition modeling of additive manufacturing (AM). This design approach differs from topology optimization, since the topology op…