A new generation of material: Printed Composite Honeycomb by Ultimate Jets.
#1
Thread Starter
A new generation of material: Printed Composite Honeycomb by Ultimate Jets.
PCH is a new generation of material that I've been working on for several months now.
It is a hybrid material made of glass fiber or carbon fiber laid up on a 3D printed honeycomb structure. What makes the strength of the material is actually the printing material. It is what I call PYCABS: a mix of ballistic grade Polycarbonate and ABS.
http://www.stratasys.com/materials/fdm/pc-abs
The result is a bullet proof material that is both very stiff and shock absorbing.
I am quite proud of this as it is the first time that I come up with something as original and high performance as this. As far as I am aware of, this is unique in the industry.
The advantages of this material are the following:
The limitations are the fact that the part size cannot be bigger than the printing bed. In my case: 20 cm by 30 cm.
Here is a video of an AD Diamond door structure printing:
https://vimeo.com/101165827 An example of a fairly complex door structure designed by CAD:
And the printed result. The glass fiber layup is on the other side of the door and makes the part quite white:
The door attaches to the main strut with CAD designed clips that conform to both the strut shape and match the door reinforcements. The full digital process allows for a fitting tolerance of 02 mm.
I am finishing the Diamond doors kit with this technique first, then I will carry on to the Scorpion, Super Scorpion and Phoenix.
Other cool designs about to come as well. Stay tuned...
It is a hybrid material made of glass fiber or carbon fiber laid up on a 3D printed honeycomb structure. What makes the strength of the material is actually the printing material. It is what I call PYCABS: a mix of ballistic grade Polycarbonate and ABS.
http://www.stratasys.com/materials/fdm/pc-abs
The result is a bullet proof material that is both very stiff and shock absorbing.
I am quite proud of this as it is the first time that I come up with something as original and high performance as this. As far as I am aware of, this is unique in the industry.
The advantages of this material are the following:
- 3D printing allows for extremely complex shapes to be created.
- The resulting composite structure is light, stiff and shock absorbing.
- The full digital production chain enables a fitting tolerance of 0.2 mm.
- The production time is short, and material cost reasonable.
The limitations are the fact that the part size cannot be bigger than the printing bed. In my case: 20 cm by 30 cm.
Here is a video of an AD Diamond door structure printing:
https://vimeo.com/101165827 An example of a fairly complex door structure designed by CAD:
And the printed result. The glass fiber layup is on the other side of the door and makes the part quite white:
The door attaches to the main strut with CAD designed clips that conform to both the strut shape and match the door reinforcements. The full digital process allows for a fitting tolerance of 02 mm.
I am finishing the Diamond doors kit with this technique first, then I will carry on to the Scorpion, Super Scorpion and Phoenix.
Other cool designs about to come as well. Stay tuned...
Last edited by olnico; 07-25-2014 at 04:59 AM.
#5
My Feedback: (57)
My supplier has a 20"x30"x18" capability printer. Ive thought about starting a business printing small parts., like true to scale ordinance, scale landing gear,cockpits and and custom made work.
Ive been able to succesfully make dynamic parts in a single pass (that is parts that mechanically move like pinned linkeages).
I also have the ability to print Titanium, Steel, and Aluminum parts, and a myriad of Nylons and other reinforced fibers. I really wonder if it would be $ feasible here in the states.
Ive been able to succesfully make dynamic parts in a single pass (that is parts that mechanically move like pinned linkeages).
I also have the ability to print Titanium, Steel, and Aluminum parts, and a myriad of Nylons and other reinforced fibers. I really wonder if it would be $ feasible here in the states.
#9
My Feedback: (44)
Well under the material listed is lists the printer we have at work which is a Fortus 400 MC, this machine is over $150K USD
http://www.stratasys.com/materials/fdm/pc-abs
I agree that large structural parts would not be light based on experience from prototypes we print on that machine.
For small scale details the 3D printer is the way to go!
http://www.stratasys.com/materials/fdm/pc-abs
I agree that large structural parts would not be light based on experience from prototypes we print on that machine.
For small scale details the 3D printer is the way to go!
#10
Thread Starter
That's an interesting point.
Actually, a composite panel printed with regular ABS structure would come out quite heavy.
PYCABS is much lighter than regular ABS when properly laid up with the appropriate technique. That is because tensile strength and furthermore flexural strength are 30&% higher.
That enables printing very thin honeycomb structures.
Here is the weight of a gear door produced in PCH:
And the same door produced with a quadriaxial 400 grs/m2 carbon fiber layup and 3 mm balsa core;
In that case, PCH is 10% lighter than a carbon fiber/ balsa structure.
I could produce a similar part from vaccum moulded aramid nomex/ 200 grs carbon for about 24 grs as well but at a considerable expense.
We're talking about sub 30 grs parts anyway, which is very light.
A complete gear doors set with all the clamps come at about 150 grs.
Actually, a composite panel printed with regular ABS structure would come out quite heavy.
PYCABS is much lighter than regular ABS when properly laid up with the appropriate technique. That is because tensile strength and furthermore flexural strength are 30&% higher.
That enables printing very thin honeycomb structures.
Here is the weight of a gear door produced in PCH:
And the same door produced with a quadriaxial 400 grs/m2 carbon fiber layup and 3 mm balsa core;
In that case, PCH is 10% lighter than a carbon fiber/ balsa structure.
I could produce a similar part from vaccum moulded aramid nomex/ 200 grs carbon for about 24 grs as well but at a considerable expense.
We're talking about sub 30 grs parts anyway, which is very light.
A complete gear doors set with all the clamps come at about 150 grs.
Last edited by olnico; 07-25-2014 at 10:09 AM.
#11
Thread Starter
No printer on the market is capable of producing a part like this. The trick is combining a 3D printed core with the appropriate vacuum molded layup.
It took me a lot of efforts and thinking in combining these two techniques. One of the catch is to find the appropriate layup resin/ material combination.
The other difficult part is to produce the right honeycomb pattern and thickness to achieve stiffness, light weight and proper inter-layers adhesion.
It took me a lot of efforts and thinking in combining these two techniques. One of the catch is to find the appropriate layup resin/ material combination.
The other difficult part is to produce the right honeycomb pattern and thickness to achieve stiffness, light weight and proper inter-layers adhesion.
#13
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Hi Oli,
well done for having vision and innovating ! It's much easier to sit at a keyboard and knock someone's achievement ,than get off your arse
and do something new and interesting!
Well done and keep up the good work ,always enjoy your articles etc and have picked up some useful tips , thank you.
regards Jon Sykes.
well done for having vision and innovating ! It's much easier to sit at a keyboard and knock someone's achievement ,than get off your arse
and do something new and interesting!
Well done and keep up the good work ,always enjoy your articles etc and have picked up some useful tips , thank you.
regards Jon Sykes.
#14
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Location: farnborough, , UNITED KINGDOM
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Another advantage in this technique from what I can see is you can in-build fixing areas so that where crushing occurs normally with a honeycomb laminate when using say a nut and bolt this offers you a bespoke internal structure to allow for this sort of fixing application.
Nice product.
marcs
Nice product.
marcs
#15
Thread Starter
Another advantage in this technique from what I can see is you can in-build fixing areas so that where crushing occurs normally with a honeycomb laminate when using say a nut and bolt this offers you a bespoke internal structure to allow for this sort of fixing application.
Nice product.
marcs
Nice product.
marcs
The other door includes the actuating horn and piano hinge attachment slot.
The door clips have printed threads so that there is not even any need for a nut in there!
Thanks for the kind words!
#16
Thread Starter
Hi Oli,
well done for having vision and innovating ! It's much easier to sit at a keyboard and knock someone's achievement ,than get off your arse
and do something new and interesting!
Well done and keep up the good work ,always enjoy your articles etc and have picked up some useful tips , thank you.
regards Jon Sykes.
well done for having vision and innovating ! It's much easier to sit at a keyboard and knock someone's achievement ,than get off your arse
and do something new and interesting!
Well done and keep up the good work ,always enjoy your articles etc and have picked up some useful tips , thank you.
regards Jon Sykes.
The more tips you pickup, the more significant my work becomes!
#17
Join Date: Nov 2003
Location: Curitiba, Parana, BRAZIL
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This material is very promising.. however due to the cost of printers seems that this is still out of reach for most modelers for now.
Stretching a bit the concept maybe it would be possible to build a complete airplane using this plastic honeycomb..someone offering a kit like this but with rigid,full surface detailing would be fantastic:
http://bukvorez.com/index.php?option...d=78&Itemid=83
Stretching a bit the concept maybe it would be possible to build a complete airplane using this plastic honeycomb..someone offering a kit like this but with rigid,full surface detailing would be fantastic:
http://bukvorez.com/index.php?option...d=78&Itemid=83
#19
My Feedback: (57)
It would be possible if you could mix materials. Im not sure it can be done right now....I will ask. It would be asweome if you could model something with soft Nylon 12, then reinforce with thin aluminum where specified.
You can get the Makerbot 2 for ~$3K......but again I dont think you will get the finish that you want on a single pass.......however you can make cockpits, ordnance, specialty hinges, lots of goodies.
You can get the Makerbot 2 for ~$3K......but again I dont think you will get the finish that you want on a single pass.......however you can make cockpits, ordnance, specialty hinges, lots of goodies.
#22
Thread Starter
For information, I am now working with my filament supplier on experimental materials. Among which are:
Carbon fiber reinforced ABS
Carbon fiber reinforced PLA
Carbon fiber reinforced PYCABS
New formulated PYCABS with more polycarbonate per kg
All these materials are more difficult to print and subject to nozzle clogging ( except for the last one ) but will provide amazing results.
Also for information, the university of Harvard is working on a similar project with slightly different techniques but fairly similar results.
Have a look here:
http://www.seas.harvard.edu/news/201...-of-balsa-wood
Carbon fiber reinforced ABS
Carbon fiber reinforced PLA
Carbon fiber reinforced PYCABS
New formulated PYCABS with more polycarbonate per kg
All these materials are more difficult to print and subject to nozzle clogging ( except for the last one ) but will provide amazing results.
Also for information, the university of Harvard is working on a similar project with slightly different techniques but fairly similar results.
Have a look here:
http://www.seas.harvard.edu/news/201...-of-balsa-wood
#23
Thread Starter
I am also working with mathematicians who have implemented new 3D honeycomb generation patterns. These exhibit compressibility resistance in 3 directions instead of 1 direction for classical nomex/ paper honeycomb.
The algorithm used can be tweaked to generate a larger thickness ondulation and thus create 3D honeycomb cells exactly similar on x, y and z axis.
The algorithm used can be tweaked to generate a larger thickness ondulation and thus create 3D honeycomb cells exactly similar on x, y and z axis.
Last edited by olnico; 09-02-2014 at 04:26 AM.