LargeDuroPrint – Large-scale thermoset 3D printing for aerospace applications
Material and process development for extrusion-based large-scale thermoset 3D printing using an ultrasonic mixing head.
Project Partners
University of Bayreuth
Duration
01.01.2022 – 31.12.2024
Funding authority
Bavarian Ministry of Economic Affairs, Regional Development and Energy
Motivation
Additive manufacturing offers significant advantages over conventional manufacturing processes thanks to the high design freedom and the resulting lightweight construction potential. However, already established additive manufacturing processes also have some disadvantages. For example, high energy requirements and high material costs for metals or increased creep tendency and warpage for thermoplastics. On the other hand, thermosets have above-average thermomechanical properties. Since the development stage of additive manufacturing with thermosets is still very low and almost limited to desktop printers, the project aims to develop the materials and the process for large-volume thermoset 3D printing.
Method
The aim of the project is to develop a material system in combination with a novel resin-based additive processing method. On the process side, the components of the material system will first be homogenized using an ultrasonic mixing head and then deposited in defined layers via extrusion. An additive processable material system is being developed that meets the specifications required in the aerospace industry. Simulation approaches will be integrated into the material as well as the process development. The project is aimed at the production of large-scale, customized geometries for the aerospace industry.
Acknowledgement
The chair thanks the Bavarian Ministry of Economic Affairs, Regional Development and Energy for the funding under the scheme “Förderprogramm Luftfahrt BayLu-25-II”.
Contact Persons
Dr.-Ing. Swen Zaremba