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Additive manufacturing of carbon fiber-reinforced thermoset composites via in-situ thermal curing

Author

Listed:
  • Carter F. Dojan

    (Colorado State University)

  • Morteza Ziaee

    (Colorado State University)

  • Alireza Masoumipour

    (Colorado State University)

  • Samuel J. Radosevich

    (Colorado State University)

  • Mostafa Yourdkhani

    (Colorado State University
    Colorado State University
    Arizona State University)

Abstract

Fiber-reinforced polymer composites are lightweight structural materials widely used in the transportation and energy industries. Current approaches for the manufacture of composites require expensive tooling and long, energy-intensive processing, resulting in a high cost of manufacturing, limited design complexity, and low fabrication rates. Here, we report rapid, scalable, and energy-efficient additive manufacturing of fiber-reinforced thermoset composites, while eliminating the need for tooling or molds. Use of a thermoresponsive thermoset resin as the matrix of composites and localized, remote heating of carbon fiber reinforcements via photothermal conversion enables rapid, in-situ curing of composites without further post-processing. Rapid curing and phase transformation of the matrix thermoset, from a liquid or viscous resin to a rigid polymer, immediately upon deposition by a robotic platform, allows for the high-fidelity, freeform manufacturing of discontinuous and continuous fiber-reinforced composites without using sacrificial support materials. This method is applicable to a variety of industries and will enable rapid and scalable manufacture of composite parts and tooling as well as on-demand repair of composite structures.

Suggested Citation

  • Carter F. Dojan & Morteza Ziaee & Alireza Masoumipour & Samuel J. Radosevich & Mostafa Yourdkhani, 2025. "Additive manufacturing of carbon fiber-reinforced thermoset composites via in-situ thermal curing," Nature Communications, Nature, vol. 16(1), pages 1-10, December.
    • Handle: RePEc:nat:natcom:v:16:y:2025:i:1:d:10.1038_s41467-025-59848-2
    DOI: 10.1038/s41467-025-59848-2
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    References listed on IDEAS

    as
    1. Mayank Garg & Jia En Aw & Xiang Zhang & Polette J. Centellas & Leon M. Dean & Evan M. Lloyd & Ian D. Robertson & Yiqiao Liu & Mostafa Yourdkhani & Jeffrey S. Moore & Philippe H. Geubelle & Nancy R. So, 2021. "Rapid synchronized fabrication of vascularized thermosets and composites," Nature Communications, Nature, vol. 12(1), pages 1-9, December.
    2. Junzhe Zhu & Qiang Zhang & Tianqing Yang & Yu Liu & Ren Liu, 2020. "3D printing of multi-scalable structures via high penetration near-infrared photopolymerization," Nature Communications, Nature, vol. 11(1), pages 1-7, December.
    3. Ian D. Robertson & Mostafa Yourdkhani & Polette J. Centellas & Jia En Aw & Douglas G. Ivanoff & Elyas Goli & Evan M. Lloyd & Leon M. Dean & Nancy R. Sottos & Philippe H. Geubelle & Jeffrey S. Moore & , 2018. "Rapid energy-efficient manufacturing of polymers and composites via frontal polymerization," Nature, Nature, vol. 557(7704), pages 223-227, May.
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