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Description
Application of Carbon Fiber Reinforced Polymers (CFRP) as structural components in the aerospace, automotive, military, electronics and defence sectors is highly desired due to their low weight, low price, and decreased operational cost in comparison to metal components. However, CFRP suffer from the low electrical conductivity through their thickness, and by this they are not able to replace the metallic components. The project 3DforCOMP aims at developing a technology for increasing the through the thickness electrical conductivity of CFRP up to values required for electromagnetic shielding. The proposed solution consists of using the Fused Filaments Fabrication (FFF) 3D printing process to print thermoplastic nanocomposites containing carbon nanotubes onto the surface of carbon fabrics. Such an approach will allow to introduce in a safe way high volumes of carbon nanotubes (up to 15wt%) into the CFRP structure, which is impossible using currently available technologies. During the CFRP manufacturing process, the printed nanocomposites will be melted and mixed with the epoxy resin resulting in an increase of not only electrical but also mechanical properties. A new type of the electrically conductive and flexible filaments based on hot melt adhesives and carbon nanotubes will be tested using an industrial 3D printer in SINTEF, Norway. At each step of the process, the electrical conductivity will be analyzed and supported by microscopic investigations of the carbon nanotubes dispersion. It will allow to understand the influence of process conditions on the electrical properties and on the electromagnetic shielding effectiveness. The developed solution will achieve TRL 7 by testing its electromagnetic shielding effectiveness in natural conditions on an airplane wing prototype at the end of the project. 3DforCOMP will be managed by a young PhD Eng. helping her to establish an independent research pathway and to achieve the D.Sc. degree in the coming future.
Summary of project results
Application of Carbon Fibers Reinforced Polymers (CFRP) as structural components is highly desired due to their low weight, corrosion resistance, high durability, flexibility, and decreased operational cost compared to metal components. However, CFRP suffers from insufficient electrical conductivity due to their thickness, and so far, metallic meshes and tapes have been used to provide electromagnetic shielding (EMI). To overcome the problem of the low electrical conductivity of CFRP, the project 3DforCOMP proposes a new approach that includes nanotechnology and additive manufacturing techniques.
hot melt adhesives and multi-walled carbon nanotubes (MWCNTs) were mixed to form the electrically conductive nanocomposites further processed into the form of filaments using the designed and built pilot line within the project. The developed electrically conductive and flexible filaments are new products with confirmed better properties than other conductive filaments. These filaments were printed onto the surface of carbon fabrics according to the developed in the project procedure and used to manufacture the CFRP panels using the autoclave industrial technique.
Analysing the electrical conductivity of CFRP containing the printed layer made of nanocomposites, it was found that an expected improvement still needs to be achieved. The reason was associated with the fact that during the manufacturing process, the nanocomposite layers were too thick. Therefore, the formation of conductive pathways through CFRP thickness was not formed. It affects the EMI shielding properties, which were similar to the reference panel in most cases. The research underscores the importance of minimizing the number of printed layers to reduce the presence of thermoplastic polymers acting as insulators. Furthermore, it emphasizes the necessity of adjusting CFRP manufacturing conditions in collaboration with potential early adopters such as automotive and aerospace companies. Although the study did not directly address the initial project challenge, it led to the development of novel conductive filaments that were not commercially available and which can be applied in sensor technology. Additionally, the project empowered the female Principal Investigator to embark on an independent research trajectory, collaborate with the SINTEF company, engage in academic conferences, and pursue further investigations in related projects, positively influencing her future scientific career.