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Item Light-assisted 3D printing of continuous carbon fiber reinforced thermoset composites(North Dakota State University, 2024) Islam, Md ZahirulPolymer 3D printing has become an emerging manufacturing technique, due to its design flexibility, however its application to produce structural components is still limited due to the poor mechanical strength and thermal stability of most 3D printed parts. Because of the superior mechanical strength of carbon fiber, 3D printing of continuous carbon fiber reinforced thermoset composites have recently been studied overcome this barrier of mechanical strength and thermal stability. Light- curing based 3D printing of continuous carbon fiber shows a promising potential, however this process also has limitations in making custom object due to fiber loop creation as the nozzle turns at the corner of the object. This study aimed to develop algorithms for light-assisted 3D printing, focusing on custom object fabrication using low-viscosity urethane acrylate and epoxy-acrylate based resins. A novel approach, laser cutting incorporated 3D printing of continuous carbon fiber reinforced thermoset composites, is presented for custom object manufacturing. Furthermore, algorithms were developed to enable the printing of various shapes, including rectangles, triangles, circles, hexagons, and grid structures. A modified algorithm was also introduced and demonstrated to simplify the printing of scalable truss structures. These proposed 3D printing technologies successfully demonstrated the manufacturing of custom objects having comparable mechanical and thermal strength with similar composites manufactured by conventional manufacturing process. Finally, this study presents an experimental approach to determine the minimum light energy required to sustain continuous fiber printing. Proper tuning of the process parameter of this proposed 3D printing technique has great potential to replace conventional manufacturing process of composites by 3D printing.Item Regolith Based Polymer Matrix Composites for In-Situ Additive Manufacturing for Long Term Extraterrestrial Missions(North Dakota State University, 2022) Matetich, ChristopherThe completed study investigated Martian regolith simulant composites’ material properties when there was variation in the type of used Martian regolith simulant. Four types of Martian regolith simulant were mixed at varying weight percent loadings with polypropylene using twin screw extrusion. Test parts were made via injection molding with all the polymeric composites, and additive manufacturing with select polymeric composites. ASTM standard based tests and ANOVA tests were completed to investigate material characteristics. Depending on the creation process, the results suggested that Martian regolith simulant type impacted several material characteristics. During material processing, a foaming behavior was observed with all the materials, especially material that used MGS-1S. Additive manufactured parts were found to be impacted by the foaming behavior. A literature based thermal breakdown study suggested that thermal releases from the Martian regolith simulants were the likely candidates for the foaming behavior.