The future of composite materials holds immense promise, particularly propelled by advancements in the automotive and aerospace sectors. As the number of electric vehicles on the road continues to grow and space exploration gains momentum, the utilization of composites in cutting-edge structural applications is poised for expansion. These advanced composites enable the creation of ultra-light, high-performance, environmentally friendly engineering structures. This not only reduces fuel consumption and emissions but also contributes to the global effort to combat climate change. This ongoing trend is expected to yield multiple benefits, including the potential for cost reduction as manufacturing processes become more refined. Furthermore, the transfer of these composite technologies to other industries is likely to foster innovation and drive progress across diverse sectors.
Milled/Chopped Fiber Composites
Space exploration is on the upswing, with space agencies and exploration companies increasingly favoring lightweight aerospace structures. These modern structures find applications in fuel tanks, habitats, rockets, and capsules, replacing conventional materials such as aluminum and titanium. Simultaneously, the adoption of 3D printing in space technologies is gaining momentum, with an increasing number of objects and components being produced using 3D printing.
3DNGEN’s Solution:
At 3DNGEN, we are pioneering these transformative developments. Our RF-curing additives are revolutionizing aerospace 3D printing. We are establishing a strong presence with a growing customer base, shaping the future of space exploration.
Continuous Fiber Composites
Carbon fiber-reinforced composites (CFRCs) are a common choice for lightweight structural materials due to their exceptional mechanical properties relative to their weight. These attributes have resulted in the extensive adoption of CFRCs in various sectors, including energy, aerospace, and automotive.
3DNGEN’s Solution:
Our CNT-coated carbon fiber technology delivers volumetric heating capabilities when exposed to radio frequencies. This innovative solution not only provides efficient volumetric heating but also enhances the fiber-matrix interfacial properties through a chemical bridging process that effectively links the fibers and matrix together.
Binder Jetting
Binder Jetting is a cost-effective, energy-efficient 3D printing method using powdered media. A liquid binding agent fuses particles to create components. Cost-effectiveness arises from low energy use and affordable materials. Rapid production reduces per-part costs, making it ideal for high-volume manufacturing.
3DNGEN’s Solution:
Our CNT-based additives are a groundbreaking solution for accelerating the drying and curing of binder jet printed components. These additives not only boost the efficiency of the manufacturing process but also contribute to substantial cost savings in production.
Post Curing
The post-curing process begins with the use of UV light to define the part’s shape during the printing process. Subsequently, the component undergoes a secondary heating phase, which plays a pivotal role in establishing the desired material properties. This approach results in the development of exceptionally robust, engineering-grade mechanical properties that stand on par with those typically associated with traditional manufacturing plastics.
3DNGEN’s Solution:
Our relentless pursuit of enhancing mechanical strength through post-curing and dual-curing techniques remains a cornerstone of our efforts. With the incorporation of our CNT-based additives, microwave curing can be employed to precisely control the post-curing process.
Thermoplastic Composite
Z-strength, the component’s strength along the Z-axis, is notably shaped by the bonding between its successive layers, which are built up in a layer-by-layer fashion. The complexity arises because most 3D printing techniques encounter difficulties in reaching Z-axis strength levels on par with the strength evident in the X and Y axes. This limitation arises from the relatively weak bonds that form between each layer of material.
3DNGEN’s Solution:
3DNGEN additives offer an innovative solution for the welding of 3D-printed thermoplastic interfaces. This process involves the application of intense localized heating through the utilization of CNTs irradiated with microwaves. This efficient technique allows for the seamless joining of thermoplastic components, providing enhanced strength and durability to the 3D-printed structures.