Prediction of micro impregnation phenomena in additively manufactured composite materials

Additive manufacturing is attractive to manufacture composite materials with advanced architectures and minimal wasted material. Hybrid resin composites (a composite with multiple types of resins) are of particular interest for ballistic applications, where they have been shown to increase energy absorption. The incorporation of additive manufacturing techniques in the manufacturing of composite materials opens up a unique opportunity for designing hybrid resin composites with a controlled resin distribution at the fiber tow scale. This work presents a three dimensional numerical model for predicting the wicking of resin drops into fiber tows, taking into account the interaction with neighboring drops. A parametric study is conducted with this process model to explore the influence of select parameters on resin impregnation and distribution in the tow. This will allow one to design the process to obtain a desired porosity distribution within the tow, which can then be infused with a second type of resin to form a hybrid resin composite. The model should prove useful for tailoring the properties of composites through strategic placement of resin within fiber tows.

Automated summary

This study presents a three-dimensional numerical model for predicting the impregnation and distribution of resin in fiber tows. By conducting a parametric study with this model, it is possible to design a process that achieves the desired porosity distribution within the tows, resulting in the manufacturing of hybrid resin composites. This is significant for tailoring the properties of composites by strategically placing resin within fiber tows.