On July 28, 2020, Arkema S.A. (Columbus, France) invested in Continuous Composites, the continuous fiber 3D printing technology (Continuous Fiber 3D Printing technology, the inventor of CF3D). This is an American start-up company focusing on groundbreaking composite 3D printing manufacturing technology with strong and lightweight structures.
Continuous Composites is a leading technology company that has used patented CF3D technology and complete solutions including software, hardware, materials, and motion platforms to completely change composite manufacturing technology. Its core technology is subverting the design and manufacturing capabilities of high-performance thermosetting resin composite materials.
With the accumulation of designing light-curable liquid resins, Arkema Sartomer's business line has a product called N3xtDimension, which uses continuous fiber technology to develop new solutions for the 3D printing manufacturing process. N3xtDimension is part of the 3D printing solution of the Arkema platform, providing a series of products for all major 3D manufacturing technology solutions in the world.
In September 2019, the two companies have signed a joint development agreement (JDA) to focus on the joint development of N3xtDimension light-curable resins that promote the CF3D process. It makes it possible to produce customized large-scale composite parts with high mechanical properties for applications in aviation, automobiles, energy and other fields. Current development projects include cooperation with Lockheed Martin (United States), Air Force Research Laboratory (United States) and Siemens.
Core technology principle
CF3D's 3D printing head can print continuous fibers in single and multi-bundle configurations. The print head is impregnated with fibers in place, and the mixed material of fiber + resin is cured immediately after extrusion. The motion platform of CF3D is not fixed, and there are scalable hardware solutions on robots and gantry.
Unprecedented material properties
High-performance, light-weight composite materials bring the performance and functionality of 3D printing to a new level. Through CF3D technology, materials can be customized and flexibly processed according to specific applications. This technology is opening up a new situation, which can simultaneously 3D print structural fibers (such as carbon, glass, aramid) and functional fibers (such as optics, metals) in a single-step process. Users can print sensing functions, circuits and embedded devices directly in the structure. CF3D provides innovative material solutions for the manufacturing industry.
No restrictions
CF3D is an automated process that takes advantage of the true anisotropy of continuous fibers by discrete printing in the direction of the load condition. Continuous composite material technology does not require molds, ovens and autoclaving processes, and directly realizes terminal production. CF3D can merge multiple components into one printed part and embed functions, all of which can be completed in one manufacturing process. The advantages of CF3D enable the cost of finished composite parts to be reduced exponentially, and support no matter how large or small the parts are.
Tyler Alvarado, CEO of Continuous Composites, said that their technology is not limited to 2D slicing printing, so they can make full use of the anisotropic properties of composite materials to lay directional fibers in each direction; they can also adjust the thermosetting properties for each customer's application. Resin, for example, improves modulus, or toughness, or even fire resistance. CF3D can also use thermoplastic resins for printing, and even use thermosetting and thermoplastic materials for printing in the same structure.
CF3D can print carbon fiber, glass fiber, Kevlar fiber, and even metal wires (copper wires and nichrome wires) and optical fibers, all of which can be embedded in 3D printed composite structures. This allows objects made of composite materials to sense and collect data in real time and become electronic devices to achieve monitoring functions.
Software control
CF3D technology manufactures complex designs developed by Autodesk’s AI-driven design software, and can make full use of the anisotropic properties of continuous fiber materials to optimize the load path. The excellent trajectory control and high repeatability of the Comau robot, as well as the instant curing function of the thermosetting resin used in CF3D, enable the system to quickly print large complex structures and continuous fibers without support through free space, tubes, multi-layer carbon fiber panels and free space Material bridging.
They have achieved 50-60% fiber volume in 2018, and the variable compaction of the printed laminate has been integrated into the print head. When printing the structure in free space, it is not compressed for the tool, so the merging is different. The first layer of the structure is unsupported, so there is little pressure required because there is nothing to suppress. However, the subsequent layerer can apply pressure for compaction. "
Alvarado said that using 12K carbon fiber bundles and epoxy resin, CF3D can print 16 bundles in width. The three-layer thick sample produced by it has a porosity of less than 1% and an average tensile strength of 111 ksi. This mechanical test is part of the 2017 project of the US Department of Defense contractor. It soon exceeded 200 ksi. It also completed fire, smoke and toxicity (FST) tests for internal aerospace applications.
Future vision
Continuous Composites' vision is to break the 3D printing manufacturing model and use composite materials to advance new platforms and processes. Develop solutions directly with industry leaders to ensure that CF3D technology can enter the market efficiently after commercialization. Its team, vision, and patent protection (as of July 28, 2020, it has obtained 44 US patents and 61 international PCT patents), and is igniting the next industrial revolution.