Date Approved

9-16-2021

Embargo Period

9-17-2023

Document Type

Thesis

Degree Name

M.S. Chemical Engineering

Department

Chemical Engineering

College

Henry M. Rowan College of Engineering

Advisor

Joseph F. Stanzione III, Ph.D.

Committee Member 1

Nicholas J. Alvarez, Ph.D.

Committee Member 2

Francis (Mac) Haas, Ph.D.

Committee Member 3

James A. Newell, Ph.D.

Keywords

3D Printing, Additive Manufacturing, Digital Light Projection, Stereolithography

Subject(s)

Three-dimensional printing; Vat photopolymerization

Disciplines

Chemical Engineering

Abstract

This work seeks to improve upon the existing state-of-the-art for vat photopolymerization additive manufacturing; namely, producing in-situ composites that combine the precision and high-performance materials of the vat photopolymerization with the strength of fiber-reinforced polymer composites. A custom-designed digital light projection printer was designed and built for printing composites, which includes an automated fiber tape system to place woven E-glass fiber mats in-situ. To validate the performance improvement of composites versus the neat matrix, composites were fabricated on the custom printer with hand-placed fiber mats. A high-performance, dual-cure resin was used for these studies. The effect of layer height on matrix properties was evaluated, and there was no statistically significant difference in glass transition temperature (Tg) or glassy storage modulus (E') at 25°C as a function of layer height. It was found that composites exhibited up to a 25% improvement in E' relative to the matrix (2.9 versus 3.7 GPa) at a fiber volume fraction of 4-6% and a layer height of 200 micro-m. All composites exhibited a slightly lower Tg relative to the matrix (105 versus 115°C), but there is a minimal loss of thermal properties in the composites and a modest improvement in storage modulus, even with low fiber fraction. These results suggest that parts produced with the custom printer have the potential for high-strength military applications.

Available for download on Sunday, September 17, 2023

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