Industrial Consultancy & Sponsored Research (IC&SR) , IIT Madras
An Extruder System And Method For In Situ Printing Of Particle-reinforced Composites
Technology Category/Market
Category- Advance Material & Manufacturing
Industry Classification:
Auto-components manufacturing, Aerospace composites, Medical industry and construction
Applications:
In Situ Composite Printing, Customizable Material Composition, Low-Thermal Load Applications, Small-Scale and Precision Manufacturing, Functional Graded Materials and Multi-Material Integration
Market report:
The global 3D printed composites market was valued at USD 324.79 Million in 2024 and is projected to grow to USD 8,206.65 million by 2034 with a CAGR of 38.12%
Problem Statement
- Composite materials are high-strength, lightweight materials that are used in manufacturing of custom-designed products for diverse industrial applications.
- Conventional screw extrusion methods dominate composite production. However, these methods require bulk manufacturing, inducing high mechanical/thermal loads, while limiting customization.
- Further, existing methods degrade material integrity, restrict geometric complexity, produce wastage and cannot meet the growing demand for precision and efficiency.
- There is a need for an improved method for 3D printing of reinforced composites that preserves material integrity, reduces waste, and allows precise and flexible customization.
Technology
- The technology enables in situ 3D printing of particle-reinforced composites, combining primary matrix filaments (e.g., PLA, ABS) and secondary reinforcements (powders, fibers) with precise control over reinforcement distribution and volume fractions.
- The system supports varied reinforcement volumes (controlled by a feed screw) for creating functionally graded materials, achieving specific mechanical properties in different sections of the printed object.
- Separate material feeding and controlled heat dissipation (via a heat sink and break unit) minimize thermal and mechanical loads, preserving the structural and chemical integrity of delicate reinforcements like porous natural materials
- Immediate reinforcement near the nozzle reduces waste and enables the production of small, intricate components without the need for bulk extrusion, improving cost-efficiency and resource utilization.
- The invention produces composites with superior strain-stress characteristics, ensuring high strength, durability, and reduced debonding between materials, validated through comparative performance testing against conventional extrusion methods.
Key Features/Value Proposition
- Unlike conventional extrusion methods, the invention minimizes thermal and mechanical loads, preserving the structural and chemical properties of reinforcement materials, ensuring superior composite strength and durability in the final product.
- The system enables in situ reinforcement with precise volume fraction control, supporting functionally graded materials and complex geometries, which are challenging to achieve with traditional methods requiring preset molds and simpler designs.
- By integrating reinforcement during printing, the invention reduces material waste, eliminates the need for pre-manufactured composite filaments, and allows the production of small quantities, lowering costs and improving manufacturing efficiency.
Questions about this Technology?
Contact for Licensing
Research Lab
Prof. Gnanamoorthy R
Department of Mechanical Engineering
Intellectual Property
- IITM IDF Ref 2949
- IN 202441053265 Patent Application
Technology Readiness Level
TRL 4
Technology Validated in Lab