{"id":1957,"date":"2024-12-07T23:51:34","date_gmt":"2024-12-08T07:51:34","guid":{"rendered":"https:\/\/depts.washington.edu\/lampr\/?page_id=1957"},"modified":"2025-06-13T12:24:51","modified_gmt":"2025-06-13T19:24:51","slug":"composite_am","status":"publish","type":"page","link":"https:\/\/depts.washington.edu\/lampr\/projects\/composite_am\/","title":{"rendered":"Composite AM"},"content":{"rendered":"\t\t<div data-elementor-type=\"wp-page\" data-elementor-id=\"1957\" class=\"elementor elementor-1957\">\n\t\t\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-e4317ef elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-id=\"e4317ef\" data-element_type=\"section\" data-settings=\"{&quot;background_background&quot;:&quot;classic&quot;}\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-100 elementor-top-column 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href=\"https:\/\/depts.washington.edu\/lampr\"><span class=\"hfe-breadcrumbs-text\">Home<\/span><\/a><\/li><\/ul>\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-f3b15df elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-id=\"f3b15df\" data-element_type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-100 elementor-top-column elementor-element elementor-element-9fa394f\" data-id=\"9fa394f\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-881143e elementor-widget elementor-widget-heading\" data-id=\"881143e\" data-element_type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Pushing the Boundaries of Composite Additive Manufacturing<\/h2>\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-4e92585 elementor-widget elementor-widget-text-editor\" data-id=\"4e92585\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t<p><span style=\"font-family: arial, helvetica, sans-serif; font-size: 12pt;\">Additive manufacturing (AM) is hailed for freedom in complex component design and low material waste. Originally conceived for thermoset based stereolithography, all classes of materials are now being exploited and produced in tandem with additive processes to push the possibilities of engineered structures. Excitingly suitable for this field are fiber reinforced thermoplastics, which can offer incredible strength within lightweight and recyclable multiscale<\/span><br \/><span style=\"font-family: arial, helvetica, sans-serif; font-size: 12pt;\">components. We seek to improve the quality and printability of novel high fiber volume fraction filaments, reinforced with both stiff and compliant continuous fibers. Although fused deposition modeling (FDM, commonly known as 3D printing) of continuous fiber composites can offer uniquely tailored structures, there is limited understanding on composite behavior and its dependence on the printing process mechanics. As such, filament strengths are evaluated at specific stages of printing under uniaxial tension and Weibull statistics are applied to characterize the strength distribution. To be implanted in industry, such systems must meet the rigorous standards for reliable and predictable manufacturability. Particularly when using stiff fibers, we intend to explore and overcome associated challenges of printing to produce net-shape components with high strength, reliability, and throughput.<\/span><\/p>\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-bddb837 elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-id=\"bddb837\" data-element_type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-100 elementor-top-column elementor-element elementor-element-d17fae8\" data-id=\"d17fae8\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-d42606e elementor-position-top elementor-widget elementor-widget-image-box\" data-id=\"d42606e\" data-element_type=\"widget\" data-widget_type=\"image-box.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t<div class=\"elementor-image-box-wrapper\"><figure class=\"elementor-image-box-img\"><img fetchpriority=\"high\" decoding=\"async\" width=\"1632\" height=\"1221\" src=\"https:\/\/depts.washington.edu\/lampr\/wordpress\/wp-content\/uploads\/2024\/07\/Composite-AM-cross-sections.jpg\" class=\"attachment-full size-full wp-image-2042\" alt=\"\" srcset=\"https:\/\/depts.washington.edu\/lampr\/wordpress\/wp-content\/uploads\/2024\/07\/Composite-AM-cross-sections.jpg 1632w, https:\/\/depts.washington.edu\/lampr\/wordpress\/wp-content\/uploads\/2024\/07\/Composite-AM-cross-sections-300x224.jpg 300w, https:\/\/depts.washington.edu\/lampr\/wordpress\/wp-content\/uploads\/2024\/07\/Composite-AM-cross-sections-1024x766.jpg 1024w, https:\/\/depts.washington.edu\/lampr\/wordpress\/wp-content\/uploads\/2024\/07\/Composite-AM-cross-sections-768x575.jpg 768w, https:\/\/depts.washington.edu\/lampr\/wordpress\/wp-content\/uploads\/2024\/07\/Composite-AM-cross-sections-1536x1149.jpg 1536w\" sizes=\"(max-width: 1632px) 100vw, 1632px\" \/><\/figure><div class=\"elementor-image-box-content\"><p class=\"elementor-image-box-description\">Four quadrant view of brightfield and dark field optical images showing the distribution of compliant fibers within a lab produced filament for 3D printing.<\/p><\/div><\/div>\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-63cdc39 elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-id=\"63cdc39\" data-element_type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-100 elementor-top-column elementor-element elementor-element-1fa0a89\" data-id=\"1fa0a89\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-ba0090b elementor-widget elementor-widget-text-editor\" data-id=\"ba0090b\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t<p><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Additionally, we aim to develop a new class of composite filaments inspired by the biological structural materials of dermal armors, particularly fish scales, that enable 3D printing of advanced engineering structures with superior durability. Such filaments will consist of compliant fibers with extremely high toughness imbedded in a comparatively stiff outer matrix. It is hypothesized that through careful selection and treatment of both fiber and matrix components, successful chemical bonding between the fiber and matrix interface will exhibit decreased voids and increased final part strength. The volume fraction and size distribution of additives are expected to result in a gradient of stiffness, allowing for optimization of toughness and puncture resistance of the subsequent structures. This novel filament could provide a spectrum of mechanical properties (stiffness, strength, and toughness) that can be customized to fulfill the objectives of the printed part.<\/span><\/p>\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-04fc9c7 elementor-widget elementor-widget-text-editor\" data-id=\"04fc9c7\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t<p><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">Finally, with local collaborators here in the Puget Sound, we are investigating applications for polymer-based composites within marine environments. Generally, marine composites are manufactured with traditional composite tooling and layup, and there is a poor understanding of additively produced composites material and its durability, all of which limits its practical usability. To that end, marine degradation studies are also performed in-house on polymer<\/span><br \/><span style=\"font-family: arial, helvetica, sans-serif; font-size: 14pt;\">parts produced via 3D printing.<\/span><\/p>\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-628b820 elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-id=\"628b820\" data-element_type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-100 elementor-top-column elementor-element elementor-element-8396210\" data-id=\"8396210\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-1ddbf1f elementor-position-top elementor-widget elementor-widget-image-box\" data-id=\"1ddbf1f\" data-element_type=\"widget\" data-widget_type=\"image-box.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t<div class=\"elementor-image-box-wrapper\"><figure class=\"elementor-image-box-img\"><img decoding=\"async\" width=\"2213\" height=\"854\" src=\"https:\/\/depts.washington.edu\/lampr\/wordpress\/wp-content\/uploads\/2023\/01\/mallory-graphical-abstract.jpg\" class=\"attachment-full size-full wp-image-707\" alt=\"\" srcset=\"https:\/\/depts.washington.edu\/lampr\/wordpress\/wp-content\/uploads\/2023\/01\/mallory-graphical-abstract.jpg 2213w, https:\/\/depts.washington.edu\/lampr\/wordpress\/wp-content\/uploads\/2023\/01\/mallory-graphical-abstract-300x116.jpg 300w, https:\/\/depts.washington.edu\/lampr\/wordpress\/wp-content\/uploads\/2023\/01\/mallory-graphical-abstract-1024x395.jpg 1024w, https:\/\/depts.washington.edu\/lampr\/wordpress\/wp-content\/uploads\/2023\/01\/mallory-graphical-abstract-768x296.jpg 768w, https:\/\/depts.washington.edu\/lampr\/wordpress\/wp-content\/uploads\/2023\/01\/mallory-graphical-abstract-1536x593.jpg 1536w, https:\/\/depts.washington.edu\/lampr\/wordpress\/wp-content\/uploads\/2023\/01\/mallory-graphical-abstract-2048x790.jpg 2048w\" sizes=\"(max-width: 2213px) 100vw, 2213px\" \/><\/figure><div class=\"elementor-image-box-content\"><p class=\"elementor-image-box-description\">Workflow of stiff fiber reinforced filaments, from left to right: cross-sections of currently utilized filaments, the separate stages of the printing process at which we measure filament properties, and a Weibull plot demonstrating differences in reliability and strength between fiber filaments.<\/p><\/div><\/div>\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-6210e55 elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-id=\"6210e55\" data-element_type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-100 elementor-top-column elementor-element elementor-element-6095d7c\" data-id=\"6095d7c\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-4786d74 elementor-widget-divider--view-line elementor-widget elementor-widget-divider\" data-id=\"4786d74\" data-element_type=\"widget\" data-widget_type=\"divider.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t<div class=\"elementor-divider\">\n\t\t\t<span class=\"elementor-divider-separator\">\n\t\t\t\t\t\t<\/span>\n\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-c152bf6 elementor-widget elementor-widget-heading\" data-id=\"c152bf6\" data-element_type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Select Publications<\/h2>\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-4d150ca elementor-widget elementor-widget-text-editor\" data-id=\"4d150ca\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t<p><span style=\"font-family: arial, helvetica, sans-serif; font-size: 12pt;\">M. Parker, S. Norimatsu, R. Matsuzaki, D. Arola, A Novel Filament Design for Improving Fused Filament Fabrication of Continuous Fiber Composites,\u00a0<i data-stringify-type=\"italic\">Journal of Materials Research and Technology<\/i>\u00a0<b data-stringify-type=\"bold\">37\u00a0<\/b>(2025).\u00a0<span style=\"color: #3366ff;\"><a href=\"https:\/\/doi.org\/10.1016\/j.jmrt.2025.05.251\" style=\"color: #3366ff;\">https:\/\/doi.org\/10.1016\/j.jmrt.2025.05.251<\/a><\/span>.<\/span><\/p><p><span style=\"font-family: arial, helvetica, sans-serif; font-size: 12pt; color: #000000;\">X. Wang, C. Travis, M. T. Sorna, D. Arola, Durability of ULTEM 9085 in marine environments: a consideration in fused filament fabrication of structural components, <em>Polymers<\/em> <strong>16<\/strong> (2024).<span style=\"color: #3366ff;\"><a href=\"https:\/\/doi.org\/10.3390\/polym16030350\" style=\"color: #3366ff;\"> https:\/\/doi.org\/10.3390\/polym16030350<\/a><\/span>.<\/span><\/p><p><span style=\"color: #000000;\"><span style=\"font-family: arial, helvetica, sans-serif; font-size: 12pt;\">C. Marquis, R. Song, S. Waddell, A. Luong, D. Arola, Additive manufacturing with continuous ultra-high molecular weight polyethylene yarn, <em>Materials &amp; Design<\/em> <strong>235<\/strong> (2023). <\/span><span style=\"font-family: arial, helvetica, sans-serif; font-size: 12pt;\"><span style=\"color: #3366ff;\">https:\/\/doi.org\/10.1016\/j.matdes.2023.112411<\/span>.<\/span><\/span><\/p><p><span style=\"font-family: arial, helvetica, sans-serif; font-size: 12pt; color: #000000;\">M. Parker, N. Ezeokeke, R. Matsuzaki, D. Arola, Strength and its variability in 3D printing of polymer composites with continuous fibers, <em>Materials &amp; Design <\/em><strong>225<\/strong>\u00a0(2023). <\/span><span style=\"font-family: arial, helvetica, sans-serif; font-size: 12pt; color: #000000;\"><a href=\"https:\/\/doi.org\/10.1016\/j.matdes.2022.111505\"><span style=\"color: #3366ff;\">https:\/\/doi.org\/10.1016\/j.matdes.2022.111505<\/span><\/a>.<\/span><\/p><p><span style=\"font-family: arial, helvetica, sans-serif; font-size: 12pt; color: #000000;\">M. Parker, A. Inthavong, E. Law, S. Waddell, N. Ezeokeke, R. Matsuzaki, D. Arola, 3D printing of continuous carbon fiber reinforced polyphenylene sulfide: exploring printability and importance of fiber volume fraction, <em>Additive Manufacturing <\/em><strong>54 <\/strong><\/span><span style=\"font-family: arial, helvetica, sans-serif; font-size: 12pt; color: #000000;\">(2022).<\/span><span style=\"font-family: arial, helvetica, sans-serif; font-size: 12pt; color: #000000;\"><a href=\"https:\/\/doi.org\/10.1016\/j.addma.2022.102763\"><span style=\"color: #3366ff;\"> https:\/\/doi.org\/10.1016\/j.addma.2022.102763<\/span><\/a>.<\/span><\/p><p><span style=\"font-family: arial, helvetica, sans-serif; font-size: 12pt; color: #000000;\">S. Waddell, E. Law, A. Inthavong, M. Parker, D. Arola, Optimization and characterization of printing parameters on a novel continuous carbon fiber composite material for 3D printing, <em>URMSE<\/em> <strong>1<\/strong> (2020). <span style=\"color: #3366ff;\"><a href=\"https:\/\/doi.org\/10.6069\/ZDQW-PW89\"><span style=\"color: #3366ff;\">https:\/\/doi.org\/10.6069\/ZDQW-PW89<\/span><\/a>.<\/span><\/span><\/p>\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-d878841 elementor-widget-divider--view-line elementor-widget elementor-widget-divider\" data-id=\"d878841\" data-element_type=\"widget\" data-widget_type=\"divider.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t<div class=\"elementor-divider\">\n\t\t\t<span class=\"elementor-divider-separator\">\n\t\t\t\t\t\t<\/span>\n\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-2186a02 elementor-align-center elementor-widget elementor-widget-button\" data-id=\"2186a02\" data-element_type=\"widget\" data-widget_type=\"button.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t<div class=\"elementor-button-wrapper\">\n\t\t\t\t\t<a class=\"elementor-button elementor-button-link elementor-size-sm\" href=\"https:\/\/depts.washington.edu\/lampr\/projects\/\">\n\t\t\t\t\t\t<span class=\"elementor-button-content-wrapper\">\n\t\t\t\t\t\t\t\t\t<span class=\"elementor-button-text\">Back to Projects Page<\/span>\n\t\t\t\t\t<\/span>\n\t\t\t\t\t<\/a>\n\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<\/div>\n\t\t","protected":false},"excerpt":{"rendered":"<p>Menu Home Capabilities Current Projects People Sponsors Wiki Home Pushing the Boundaries of Composite Additive Manufacturing Additive manufacturing (AM) is hailed for freedom in complex component design and low material waste. Originally conceived for thermoset based stereolithography, all classes of materials are now being exploited and produced in tandem with [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":2042,"parent":23,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"elementor_canvas","meta":{"footnotes":""},"class_list":["post-1957","page","type-page","status-publish","has-post-thumbnail","hentry"],"_links":{"self":[{"href":"https:\/\/depts.washington.edu\/lampr\/wp-json\/wp\/v2\/pages\/1957","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/depts.washington.edu\/lampr\/wp-json\/wp\/v2\/pages"}],"about":[{"href":"https:\/\/depts.washington.edu\/lampr\/wp-json\/wp\/v2\/types\/page"}],"author":[{"embeddable":true,"href":"https:\/\/depts.washington.edu\/lampr\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/depts.washington.edu\/lampr\/wp-json\/wp\/v2\/comments?post=1957"}],"version-history":[{"count":42,"href":"https:\/\/depts.washington.edu\/lampr\/wp-json\/wp\/v2\/pages\/1957\/revisions"}],"predecessor-version":[{"id":2813,"href":"https:\/\/depts.washington.edu\/lampr\/wp-json\/wp\/v2\/pages\/1957\/revisions\/2813"}],"up":[{"embeddable":true,"href":"https:\/\/depts.washington.edu\/lampr\/wp-json\/wp\/v2\/pages\/23"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/depts.washington.edu\/lampr\/wp-json\/wp\/v2\/media\/2042"}],"wp:attachment":[{"href":"https:\/\/depts.washington.edu\/lampr\/wp-json\/wp\/v2\/media?parent=1957"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}