Industrial Consultancy & Sponsored Research (IC&SR) , IIT Madras
Technology Category/ Market
Category – Additive Manufacturing
Applications– Applications include aerospace, automobile, defense, and marine sectors, where high mechanical properties and corrosion resistance are crucial.
Industry- Aerospace, automotive, defense and marine sectors.
Market – Global additive manufacturing market is expected to grow from $13.16 billion in 2022 to $16.06 billion in 2023 at a CAGR of 22.%.
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Problem Statement
- Conventional manufacturing of Fiber-Reinforced Polymer (FRP) parts is expensive and prone to defects due to the nonhomogeneous and abrasive nature of FRPs and difficulties in joining and machining to fabricate complex components.
- Additive manufacturing (AM) offers advantages in fabricating complex structures but faces challenges in ensuring proper mixing and curing of matrix materials in continuous fiber-reinforced composites.
- Existing AM methods lack control over the ratio of matrix components and can result in improper curing, making them unsuitable for aerospace-grade polymers.
- There is a need for an innovative Liquid Deposition Modeling system to address these setbacks and enable the additive manufacturing of continuous fiber-reinforced thermoset polymer composites effectively.
Technology
- The technology involves additive manufacturing of continuous fiber-reinforced thermoset polymer composites using liquid deposition modeling. (Fig. 1)
- It is designed for 3D printing of composite parts with fiber reinforcement (carbon, glass, kevlar) and a thermoset polymer matrix (e.g., epoxy resin with a specific hardener).
- The method allows for varying the percentage of reinforcement and matrix based on specific requirements. (Fig. 2)
- The system can lay fibers in different orientations based on the design to achieve desired mechanical properties in different directions.
- The process is rapid, with curing times reduced from 24 hours in conventional manufacturing to about 30 minutes at room temperature, followed by a post-cure at higher temperature of 200-220°C for 2-3 hours for proper bonding between matrix and fiber.
Key Features/ Value Proposition
High-Performance Applications:
- The technology enables the production of composite parts with exceptional mechanical properties, making it ideal for aerospace, automobile, defense, and marine industries.
Customizable Material Composition:
- The method allows for flexible control of the percentage of reinforcement and matrix, tailoring materials to specific applications.
Versatile Fiber Orientation:
- The system can lay up fibers in various orientations, ensuring that mechanical properties align with the desired direction of stress.
Rapid Curing Process:
- Significantly reduces curing time from 24 hours to just 30 minutes at room temperature, enhancing production efficiency.
Enhanced Bonding:
- Post-curing at elevated temperatures (200-220°C for 2-3 hours) ensures proper bonding between the matrix and fiber, guaranteeing the quality of the final composite part.
Questions about this Technology?
Contact for Licensing
sm-marketing@imail.iitm.ac.in
ipoffice2@iitm.ac.in
Research Lab
Prof. Soundarapandian S,
Department of Mechanical Engineering
Intellectual Property
- IITM IDF Ref. 2011
- IN 443495 – Patent Granted
Technology Readiness Level
TRL – 4
Technology validated in lab scale.