Fused Filament Fabrication (FFF) of novel material forms for sustainable high-quality composite structures

This project aims to address the demand for sustainable composite materials in various industries, specifically in reducing the waste associated with their use. Composite structures currently face issues with manufacture defects, poor repairability and recyclability. This leads to large waste, with good quality parts being scrapped due to minor defects. Advancements in recycled carbon material forms such as Discontinuous Aligned Fibre Filament (DcAFF) provide a means to improve the sustainability and performance of the manufacture process of composites.

The project aims to develop a novel bi-matrix system for Fused Filament Fabrication (FFF), consisting of Covalent Adaptive Networks (CANs) and fast-curing resins. The primary objective of the work is to enhance the mechanical properties and printability of composite parts by addressing the limitations in porosity, fibre volume fraction, steering and inter-ply adhesion. Improvements in rheological control of the matrix system aim to make FFF a viable method for manufacture of high performance and sustainable components.

The potential applications of this research cover industries such as aerospace, automotive wind energy where high strength and lightweight materials are key. By developing a more efficient and sustainable manufacture process, the outcome could drastically reduce waste material, and the environmental impact involved in composite use. The use of recycled material forms and improved repairability properties will further contribute to a greater towards more sustainable composite manufacture practises.

The novelty of the research is found in the unique introduction of CANs in the FFF process. CANs possess desirable mechanical and chemical properties, with notably, the ability to undergo re-bonding after curing, making them well suited for repairability and recyclable composites. The DcAFF process and the introduction of CANs aims to push the boundaries of current FFF processes by combining sustainable...