Free-Standing 3D Printing of Epoxy-Vinyl Ether Structures Using Radical-Induced Cationic Frontal Polymerization.

The application of frontal polymerization to additive manufacturing has advantages in energy consumption and speed of printing. Additionally, with frontal polymerization, it is possible to print free-standing structures that require no supports. A resin was developed using a mixture of epoxies and vinyl ether with an iodonium salt and peroxide initiating system that frontally polymerizes through radical-induced cationic frontal polymerization. The formulation, which was optimized for reactivity, physical properties, and rheology, allowed the printing of free-standing structures. Increasing ratios of vinyl ether and reactive cycloaliphatic epoxide were found to increase the front velocity. Addition of carbon nanofibers increased the front velocity more than the addition of milled carbon fibers. The resin filled with carbon nanofibers and fumed silica exhibited shear-thinning behavior and was suitable for extrusion-based printing at a weight fraction of 4 wt %. A desktop 3D printer was modified to control resin extrusion and deposition with a digital syringe dispenser. Flexural properties of molded and 3D-printed specimens showed that specimens printed in the transverse direction exhibited the lowest strength, likely due to the presence of voids, adhesion issues between filaments, and preferential carbon nanofiber alignment along the filaments. Finally, free-standing printing of single, angled filaments and helical geometries was successfully demonstrated by coordinating ultraviolet-based reaction initiation, low air pressure for resin extrusion, and printing speed to match front velocity.

Disassembly Study of Ultrasonically Welded Thermoplastic Composite Joints via Resistance Heating.

This manuscript explores the disassembly potential of ultrasonically welded thermoplastic composite joints for reuse or recycling through resistance heating via a nanocomposite film located at the welded interface. Nanocomposite films containing multi-walled carbon nanotubes (MWCNTs) were characterized for thermo-electrical behavior to assess self-heating. It was generally observed that maximum temperature increased with MWCNT and film thickness. To demonstrate potential for disassembly, glass fiber/polypropylene adherends were welded with nanocomposite films. Shear stress during disassembly was measured for three initial adherend's surface temperatures. It was found that the required tensile load decreased by over 90% at the highest temperatures, effectively demonstrating the potential for disassembly via electrically conductive films. Fracture surfaces suggested that disassembly was facilitated through a combination of nanocomposite and matrix melting and weakened fiber-matrix interface. Limitations, such as slow heating rates and the loss of contact at the interface, imply that the method could be more suited for recycling, instead of repair and reuse, as the heat-affected zone extended through the adherends' thickness at the overlap during heating.

Improved Biocompatible, Flexible Mesh Composites for Implant Applications via Hydroxyapatite Coating with Potential for 3-Dimensional Extracellular Matrix Network and Bone Regeneration.

Hydroxyapatite (HA)-coated metals are biocompatible composites, which have potential for various applications for bone replacement and regeneration in the human body. In this study, we proposed the design of biocompatible, flexible composite implants by using a metal mesh as substrate and HA coating as bone regenerative stimulant derived from a simple sol-gel method. Experiments were performed to understand the effect of coating method (dip-coating and drop casting), substrate material (titanium and stainless steel) and substrate mesh characteristics (mesh size, weave pattern) on implant's performance. HA-coated samples were characterized by X-ray diffractometer, transmission electron microscope, field-emission scanning electron microscope, nanoindenter, polarization and electrochemical impedance spectroscopy, and biocompatibility test. Pure or biphasic nanorod HA coating was obtained on mesh substrates with thicknesses varying from 4.0 to 7.9 µm. Different coating procedures and number of layers did not affect crystal structure, shape, or most intense plane reflections of the HA coating. Moduli of elasticity below 18.5 GPa were reported for HA-coated samples, falling within the range of natural skull bone. Coated samples led to at least 90% cell viability and up to 99.5% extracellular matrix coverage into a 3-dimensional network (16.4% to 76.5% higher than bare substrates). Fluorescent imaging showed no antagonistic effect of the coatings on osteogenic differentiation. Finer mesh size enhanced coating coverage and adhesion, but a low number of HA layers was preferable to maintain open mesh areas promoting extracellular matrix formation. Finally, electrochemical behavior studies revealed that, although corrosion protection for HA-coated samples was generally higher than bare samples, galvanic corrosion occurred on some samples. Overall, the results indicated that while HA-coated titanium grade 1 showed the best performance as a potential implant, HA-coated stainless steel 316 with the finest mesh size constitutes an adequate, lower cost alternative.

Out-of-autoclave manufacturing of GLARE panels using resistance heating.

Autoclave manufacturing of fibre metal laminates, such as GLARE, is an expensive process. Therefore, there is an increasing interest to find cost-effective out-of-autoclave manufacturing processes without diminishing the laminate quality. The aim of this study is to evaluate the quality of fibre metal laminate panels adhesively bonded and cured using resistance heating. Three manufacturing processes are compared for different layups with an embedded steel mesh at the mid-plane: autoclave curing, resistance bonding of two (autoclave-cured) panels and complete out-of-autoclave resistance curing of panels. Interlaminar shear strength tests and optical microscopy analysis showed that resistance bonding is a promising technique, leading to results comparable to autoclave curing. Resistance curing led to an interlaminar shear strength decrease of 30-60%. A study of the correlation between degree of cure and distance from the mesh revealed the potential of resistance bonding to be used for flexible embedded mesh geometries and on-site repairs.

Ultrasonic Welding of Thermoplastic Composite Coupons for Mechanical Characterization of Welded Joints through Single Lap Shear Testing.

This paper presents a novel straightforward method for ultrasonic welding of thermoplastic-composite coupons in optimum processing conditions. The ultrasonic welding process described in this paper is based on three main pillars. Firstly, flat energy directors are used for preferential heat generation at the joining interface during the welding process. A flat energy director is a neat thermoplastic resin film that is placed between the parts to be joined prior to the welding process and heats up preferentially owing to its lower compressive stiffness relative to the composite substrates. Consequently, flat energy directors provide a simple solution that does not require molding of resin protrusions on the surfaces of the composite substrates, as opposed to ultrasonic welding of unreinforced plastics. Secondly, the process data provided by the ultrasonic welder is used to rapidly define the optimum welding parameters for any thermoplastic composite material combination. Thirdly, displacement control is used in the welding process to ensure consistent quality of the welded joints. According to this method, thermoplastic-composite flat coupons are individually welded in a single lap configuration. Mechanical testing of the welded coupons allows determining the apparent lap shear strength of the joints, which is one of the properties most commonly used to quantify the strength of thermoplastic composite welded joints.