Fabrication of a continuous carbon fiber-reinforced phenolic resin composites via in situ-curing 3D printing technology

An in situ-curing 3D printing technology was developed, which comprised resin impregnation, 3D printing/pre-curing and post-curing processes. Continuous carbon fiber-reinforced thermosetting phenolic resin (CF/PF) composites were fabricated based on that. The selection of pre-curing temperature was the key to successful printing. The deviation distances of prepregs during 3D printing, degrees of curing and defect volumes of the composites after 3D printing and post-curing were used to determine the pre-curing temperature. With the optimum pre-curing temperature of 260 degrees C, the deviation distance of the prepreg was 8.57 mm, defect volume of post-cured CF/PF composite was 12.1% and its mechanical properties were optimal. The degree of curing was 80.7% after 3D printing, which could maintain the structure integrity during the 3D printing and post-curing processes.

Automated summary

An in situ-curing 3D printing technology was developed, which involved resin impregnation, 3D printing/pre-curing, and post-curing processes. Continuous carbon fiber-reinforced thermosetting phenolic resin (CF/PF) composites were successfully fabricated. The selection of the pre-curing temperature was crucial for the printing process. The deviation distances of the prepregs, degrees of curing, and defect volumes of the composites were used to determine the appropriate pre-curing temperature. With a pre-curing temperature of 260 degrees C, the printed CF/PF composites showed optimal mechanical properties with minimal defects.