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DOE OSTI · 2573592

Embedded 3D printing of isotropically enhanced lattice structure with programmable elasticity via three-dimensional fiber alignment

Chen, Qiyi [University of California, Berkeley, CA (United States)]·Shishvan, Siamak S. [University of Cambridge (United Kingdom)] (ORCID:0000000229452081)·Zhang, Shuo [University of California, Berkeley, CA (United States)]·Shaikeea, Angkur J.D. [University of Cambridge (United Kingdom)]·Park, James Juyoung [University of California, Berkeley, CA (United States)]·Xu, Zhenpeng [University of California, Berkeley, CA (United States)]·Kim, Seokpum [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000250312585)·Hmeidat, Nadim S. [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000296690426)·Hemminger, Hannelore [University of California, Los Angeles, CA (United States)] (ORCID:000000029585103X)·Deshpande, Vikram S. [University of Cambridge (United Kingdom)] (ORCID:0000000338993573)·Zheng, Xiaoyu [University of California, Berkeley, CA (United States)] (ORCID:0000000186855728)
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Abstract

Engineered composites with fiber orientation in a complete three-dimensional (3D) context are highly desired for maximizing structural performance as they mimic the well-organized fiber arrangement in natural composites. However, most fabrication techniques lack the capability for through-plane (z-axis) alignment, limiting the possibility for structural design and performance optimization. In this study, we present an embedded 3D printing approach that enables complete 3D fiber alignment, including region-specific alignment control along the through-plane direction. Our method utilizes the extrusion and suspension of composite inks within a supporting matrix. By regionally adjusting the ink extrusion rate and nozzle translation rate, we locally manipulated the fiber arrangement within the composite 3D architecture. Here, we demonstrate that the 3D alignment of carbon fibers in a structural composite significantly enhances both mechanical properties and thermal conductivity in the in-plane and through-plane directions. Furthermore, by strategically arranging regional fiber orientations within micro-architected materials, we fabricated metamaterial engineered composites with programmable anisotropy ratio and directional moduli.

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36 MATERIALS SCIENCE3D alignmentEmbedded 3D printingFiber alignmentPerformance enhancementProgrammable anisotropy

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Chen, Qiyi [University of California, Berkeley, CA (United States)], Shishvan, Siamak S. [University of Cambridge (United Kingdom)] (ORCID:0000000229452081), Zhang, Shuo [University of California, Berkeley, CA (United States)], Shaikeea, Angkur J.D. [University of Cambridge (United Kingdom)], Park, James Juyoung [University of California, Berkeley, CA (United States)], Xu, Zhenpeng [University of California, Berkeley, CA (United States)], Kim, Seokpum [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000250312585), Hmeidat, Nadim S. [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000296690426), Hemminger, Hannelore [University of California, Los Angeles, CA (United States)] (ORCID:000000029585103X), Deshpande, Vikram S. [University of Cambridge (United Kingdom)] (ORCID:0000000338993573), Zheng, Xiaoyu [University of California, Berkeley, CA (United States)] (ORCID:0000000186855728). 2025-04-09. Embedded 3D printing of isotropically enhanced lattice structure with programmable elasticity via three-dimensional fiber alignment. https://doi.org/10.1016/j.addma.2025.104783

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36 MATERIALS SCIENCE↗