(539j) Freeform Additive Manufacturing of Carbon Fiber Reinforced Composites Using Dielectric Barrier Discharge-Assisted Joule Heating

We developed an innovative additive manufacturing (AM) technique for rapid printing and curing of thermosetting carbon fiber reinforced composites (CFRCs) using dielectric barrier discharge (DBD). Traditional CFRC production relies on automated fiber placement machines (AFPs) with molds and oven curing processes. Our AM method enables on-the-fly printing and curing of CFRCs without molds. Unlike many AM techniques limited to UV-curable or low viscosity resins, our approach employs DBD for in-situ heating and curing of continuous CFRCs with commercial thermosetting resins. As the composite is deposited, Joule heating induced by the DBD applicator ensures curing in the desired shape. DBD-manufactured composites exhibit properties comparable to conventionally manufactured oven composites. This method supports automatic deposition of 2D and 3D multilayered structures. Leveraging AM, this technology enables printing of high-performance, lightweight materials in any desired shape.