Manufacturing of bioinspired Bouligand structures using ultrasound assisted 3D printing

Abstract

Materials with bioinspired Bouligand structures provide a new approach to explore isotropic fiber-reinforced composites. However, it is challenging to manufacture composites with various fibers along with a three-dimensional helical structure. In this work, to accomplish the alignment of a three-dimensional (3D) helical structure of fibers in a composite material, an acoustically aligned fiber technology was incorporated with a rotating mechanism in a stereolithography 3D printer. Firstly, the formation process of acoustic standing wave was simulated and the relationship between standing wave parameters and planar line arrays was then established. Secondly, Bouligand composites with various parameters were fabricated using an acoustic-assisted 3D printing technology and the effect of the angle between the interlayer fiber arrays on the mechanical properties was experimentally measured. Finally, heat sink and meniscus structures with Bouligand structure were fabricated using carbon nanofiber and glass nanofiber, respectively. The 3D printing processing method integrating acoustic alignment technology and rotating mechanism provides a new method for fabrication of composite materials with complex fiber structures.