Sensor-integrated high-volume direct pellet continuous fiber-reinforced supportless robotic 3D printing

集成传感器的大容量直接颗粒连续纤维增强无支撑机器人 3D 打印

• 批准号: 570899-2021
• 负责人: Mertiny, Pierre
• 金额: $ 3.64万
• 依托单位: University of Alberta
• 依托单位国家: 加拿大
• 项目类别: Alliance Grants
• 财政年份: 2021
• 资助国家: 加拿大
• 起止时间: 2021-01-01 至 2022-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=723158
• 关键词: Sensor; integrated; volume; direct; pellet

Fiber-reinforced plastics (FRPs) are comprised of a polymer and a reinforcement phase such as glass and carbon fibers. While FRPs have commonly been used in high-cost applications such as in the aerospace and defense sectors, significant reductions in material costs have made FRPs attractive also to the automotive and construction industries. FRPs offer excellent stiffness- and strength-to-weight ratios, as well as high corrosion resistance, making them a high-performance alternative to metal alloys. However, the fabrication of FRP parts, especially for geometries that are not trivial like tubes and plates, remains a complex process comprising the manufacture of fiber preforms such as fabrics, followed by adding the polymer to the preform and forming and solidifying a part employing specialized tooling. This multi-step process is labor intensive, time-consuming, and prone to quality variations due to the need for human intervention. 3D printing of FRPs is an emerging field that has focused primarily on thermoplastic polymers with mostly chopped fibers, resulting in limited stiffness and tensile strength of composite parts, therefore providing little opportunity to create industrial components with enhanced performance. The present proposal aims to overcome these limitations by researching and developing a robotic direct extrusion 3D printing system capable of 3D printing continuous fiber-reinforced plastics to produce parts of industrial relevance and performance. The study will also develop sensors and manufacturing data analytics systems to ensure in line quality control of printed parts by identifying and developing (i) sensors to detect and mitigate part distortion, (2) systems to monitor the continuous fiber morphology in the part, and (iii) actively control the height of deposited layers. The project will also create special computer aided manufacturing strategies, for example, to provide two-dimensional weave capacity for 3D printed parts with true five axis movement for supportless part printing.

纤维增强塑料 (FRP) 由聚合物和增强相（例如玻璃纤维和碳纤维）组成。虽然玻璃钢通常用于航空航天和国防领域等高成本应用，但材料成本的大幅降低也使玻璃钢对汽车和建筑行业也有吸引力。 FRP 具有出色的刚度和强度重量比以及高耐腐蚀性，使其成为金属合金的高性能替代品。然而，FRP 零件的制造，特别是对于管和板等不那么简单的几何形状，仍然是一个复杂的过程，包括制造纤维预成型件（例如织物），然后将聚合物添加到预成型件中，并使用专门的材料成型和固化零件。工具。这种多步骤的过程是劳动密集型、耗时的，并且由于需要人为干预而容易出现质量变化。 FRP 的 3D 打印是一个新兴领域，主要专注于含有短切纤维的热塑性聚合物，导致复合材料零件的刚度和拉伸强度有限，因此几乎没有机会制造具有增强性能的工业组件。本提案旨在通过研究和开发机器人直接挤出 3D 打印系统来克服这些限制，该系统能够 3D 打印连续纤维增强塑料，以生产具有工业相关性和性能的零件。该研究还将开发传感器和制造数据分析系统，通过识别和开发（i）传感器来检测和减轻零件变形，（2）系统来监测零件中的连续纤维形态，以及（2）系统来确保打印零件的在线质量控制。 (iii)主动控制沉积层的高度。该项目还将创建特殊的计算机辅助制造策略，例如，为 3D 打印零件提供二维编织能力，并为无支撑零件打印提供真正的五轴运动。