CONTINUOUS FIBER 3D PRINTING USING UV-CURE EPOXY RESIN

Abstract

In this thesis, a continuous fiber single epoxy inline impregnation 3D printer head using UV cure epoxy resin is developed and manufactured. Through the design process, the final design of the printer head was achieved, and it was able to print three 3-layer fiberglass laminate composites, as well as two carbon fiber composites. Both printed composite types were compared with a hand-layup composite, serving as a benchmark. Through visual observation with the naked eye, the printed composites showed more consistency than the benchmark composites. This was further proven through microscopic imaging. Comparing the composites under 20x+ magnification showed a significant difference between void sizes in the hand-layup carbon fiber composite sample and the printed carbon fiber composite sample. The printed composite sample had significantly less voids and smaller voids than the hand-layup composite sample. In addition, the printed fiberglass composites showed to have less excess epoxy on the bottom of the composite compared to the fiberglass hand-layup composite. This is visible when looking at it and some of the spot sizes were characterized using the microscope. All in all, this proof-of-concept prototype 3D printer head using UV cure epoxy was researched, completed, and functioned as designed, capable of manufacturing multilayer laminate composite samples.