Coit, Brennan G.

Dungy, Aidan M.

Ficker, Matt K.

Gerold, Kyle

Perez, Dominic L.

Wooden, Matthew D.

English

OpenRiver@Winona State University

OpenRiver Early Year Research & Creative Mentoring 2022-2023 Early-Year Research & Creative Mentoring 9-1-2023 Welding 3D Printed Structures for Composite Sacrificial Tooling Dominic L. Perez Winona State University Kyle Gerold Winona State University Matt K. Ficker Winona State University Matthew D. Wooden Winona State University Aidan M. Dungy Winona State University See next page for additional authors Follow this and additional works at: https://openriver.winona.edu/earlyyearresearch2023 Recommended Citation Perez, Dominic L.; Gerold, Kyle; Ficker, Matt K.; Wooden, Matthew D.; Dungy, Aidan M.; and Coit, Brennan G., "Welding 3D Printed Structures for Composite Sacrificial Tooling" (2023). Early Year Research & Creative Mentoring 2022-2023. 6. https://openriver.winona.edu/earlyyearresearch2023/6 This Article is brought to you for free and open access by the Early-Year Research & Creative Mentoring at OpenRiver. It has been accepted for inclusion in Early Year Research & Creative Mentoring 2022-2023 by an authorized administrator of OpenRiver. For more information, please contact klarson@winona.edu. Authors Dominic L. Perez, Kyle Gerold, Matt K. Ficker, Matthew D. Wooden, Aidan M. Dungy, and Brennan G. Coit This article is available at OpenRiver: https://openriver.winona.edu/earlyyearresearch2023/6 Welding 3D Printed Structures for Composite Sacrificial Tooling2 years of First Year ResearchKellie Hardecopf, Alex Hilo, Regan Harvey, Tasha Kemna, Dominic Perez, Matt Ficker, Kyle Gerold, Matt Wooden, Aidan Dungy, Brennon CoitDr. Eric Kerr-Anderson, Assistant ProfessorWinona State University, Composite Materials EngineeringComposite ToolingComposites can be light, stiff, and strong.Composite Tooling can be simple or complex depending on the part geometry and processing method.As complexity increases, the cost and lead time also increases.Flat Parts on a Flat TableComplexSimpleCurved parts on a thin sheet of metal clamped to a wooden FormComplex Geometry Parts with machined, multi-cavity tooling3D Printing It is very easy to generate 3D printed parts that have complex geometries that would be difficult and time consuming to produce with conventional machining. The print time can be 20+ hours for a large part, but the touch time may be less than 30 minutes.Multiple printers can be used as a manufacturing print farm.Size and Structural issues with 3D PrintingSmall Printers Cheap Technologically mature High Detail Not big enough to print large items for composite tooling use Variety of materialsLarge Printers Expensive Depending on type/brand may be still a prototype Either low resolution or very long print times Some printers can print boats, cars, and small homes Variety of materials Even heating, surface levelness, part shifting, and plate debonding becomes more difficult as parts get largerWeak StrongWelding 3D Printed PartsThermoplastic materials processing is relatively simpleSeveral processing methods were initially screened in 2022 3D Printing Pens Friction Stirring Melt surfaces and clamp Heating copper wire clamped between two partsHeat Press Cool3D Printing PensFriction WeldingHeat and PressTensile Testing 3D Printed Welds - SetupSingle lap shear specimens were 3D printed to create ISO 527 – 1A tensile specimensSettings included: layer height of 0.15mm  wall count of 8 top/bottom set to 6 layers 20% InfillA small chamfer was added to the weld lines Tensile Testing 3D Printed Welds - ResultsThe exploratory round of welding resulted in a grouping that broke outside of the weld using both a 3D Extruding Pen and a flat smoothing soldering iron.The second round with less than 2 hours of practice resulted in several strong welds using both pen extrusion and soldering iron.Flexural Testing 3D Printed Welds - Setup1.25”4.8”Weld LengthWeld SpacingTopBottomBoth2.0”0.125”All bars were welded with 3D printing pens and smoothed with a soldering ironBaseline comparison bars were printed with no weld at 20% fill with 0.15 mm  layer height and 4 walls/tops/bottoms Each group had 5 specimens tested (135 total)0.25" 0.3125" 0.4167"Top Top TopBottom Bottom BottomBoth Both BothTop Top TopBottom Bottom BottomBoth Both BothTop Top TopBottom Bottom BottomBoth Both Both0.25"0.50"0.75"SpacingWeld LengthFlexural Testing 3D Printed Welds - ResultsIt was found that a weld length of 0.75” and spacing of 0.25” with the weld on the tensile side of the bend exceeded the strength of a standard 3D printed bar without welds.BaselineBaselineBaselineInteraction of position, length, and spacingFlexural Strength increased: As weld spacing decreased As weld length increased As weld was placed on the tensile side of the bendThere was no significant run effect or specimen effectModelling a Kyle ArmRubber bands were used to space out the measurements at 1” incrementsCaliper was used to determine principal dimensions of the ellipsesOffset planes were used to create a lofted extrusion in SolidworksSeveral pieces of a part printed on cheaper smaller printers simultaneously will be much faster than one big partPrinting parts in preferential planes for optimum strengthPrinter size, cost, and timing$10k200 hrs$10k20 hrsOrOrSacrificial ToolingTraditional tooling requires forming, machining, and polishing of metal with release agents to ensure resin does not adhere to tool. (Multiple parts produced)Sacrificial tooling is used to make fast, unique prototypes by either leaving the tool form in the part after production or cut/melted out of the part after production. (One part produced)Filament Winding Vacuum Assisted Braided sockTooling can be used to wind filament, vacuum fabric, or pull braided fabric over while the resin cures and the composite is created.Future WorkHow many layers are needed on walls, top, and bottom relative to part thickness and fill %?What part thickness is required for structural support during Vacuum Assisted processing?What material selection is compatible with Epoxy?How to program an auto generated puzzle piece parting of a large structure?Questions?First Year Research and Creative MentoringEric Kerr-Anderson, Assistant ProfessorWinona State UniversityComposite Materials Engineering

Welding 3D Printed Structures for Composite Sacrificial Tooling

https://openriver.winona.edu/cgi/viewcontent.cgi?article=1005&context=earlyyearresearch2023

Welding 3D Printed Structures for Composite Sacrificial Tooling

Abstract

Similar works

Full text

Available Versions

OpenRiver@Winona State University