Continuous Composites and Siemens Energy have successfully demonstrated continuous fiber 3D printing (CF3D®) technology for energy generator components. Through years of cooperation, the two companies have developed a thermosetting glass fiber reinforced polymer (GFRP) material that has better mechanical properties at higher temperatures, optimized the topology, and performed dynamic fiber steering to enable The anisotropic fibers are oriented in the direction of the load for customized applications.
Reduce delivery time and cost
Currently, metal casting processes are used to manufacture several generator parts, which are expensive and have a long lead time. The development of these new materials used in conjunction with the CF3D® process exceeds the material temperature requirements of generators and other applications. Demonstration achievements in the energy sector include a 5-fold reduction in manufacturing costs and a reduction in delivery time from 8-10 months to 3 weeks. Long-term downtime can save $1 million in energy and significantly reduce component weight and material waste.
Relevant personnel said that the excellent mechanical properties of CF3D®, coupled with the significant reduction in cost and delivery time, made us choose continuous composite materials. The opportunity to use AM's composite materials to replace metal generator components is a powerful breakthrough in solving the constraints we face in the energy industry, and CF3D® technology is making it possible.
High temperature CF3D ® thermosetting polymer
The two companies have jointly developed a high-temperature CF3D® thermosetting polymer that can print large and complex parts that cannot be made with traditional composite materials. The glass transition temperature (Tg) of this material is 227°C, and the strength loss is minimal at temperatures higher than Tg. The fiber volume fraction (FVF) of CF3D® printed composites is greater than 50%, and the porosity is less than 1.5%.
The use of CF3D® in the manufacture of generator components is an example. Our technology is destroying the current manufacturing process and replacing metal parts with high-performance composite materials. The relevant personnel said that our cooperation with Siemens Energy demonstrated our development and customization. The ability of material solutions with strict mechanical performance requirements extends far beyond the energy sector.