Dojan Carter F, Ziaee Morteza, Masoumipour Alireza, Radosevich Samuel J, Yourdkhani Mostafa
School of Materials Science and Engineering, Colorado State University, Fort Collins, CO, USA.
Department of Mechanical Engineering, Colorado State University, Fort Collins, CO, USA.
Nat Commun. 2025 May 20;16(1):4691. doi: 10.1038/s41467-025-59848-2.
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.
纤维增强聚合物复合材料是广泛应用于交通运输和能源行业的轻质结构材料。目前制造复合材料的方法需要昂贵的模具和漫长、耗能高的加工过程，导致制造成本高、设计复杂性有限且制造速度低。在此，我们报告了纤维增强热固性复合材料的快速、可扩展且节能的增材制造方法，同时无需模具。使用热响应性热固性树脂作为复合材料基体，并通过光热转换对碳纤维增强材料进行局部远程加热，能够实现复合材料的快速原位固化，无需进一步后处理。基体热固性材料在由机器人平台沉积后立即从液态或粘性树脂快速固化并转变为刚性聚合物，从而能够在不使用牺牲性支撑材料的情况下对间断和连续纤维增强复合材料进行高保真、自由形式制造。该方法适用于多种行业，将能够快速、可扩展地制造复合材料部件和模具，以及对复合材料结构进行按需修复。
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