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3D Printing of Syntactic Foams for Marine Applications

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Advances in Thick Section Composite and Sandwich Structures

Abstract

Syntactic foams are hollow particle filled lightweight composite materials that are widely used in structural applications in underwater marine vessels. Additive manufacturing (AM), also called 3D printing, methods are now being developed for printing parts of syntactic foams. These methods provide advantage that the entire part can be printed without the requirement of machining or joining and eliminates stress concentration locations. The present work is focused on describing the method of creating a syntactic foam filament for fused filament fabrication type printers and then developing parameters for printing syntactic foams parts using commercial printers. High density polyethylene resin is used as the matrix material with fly ash cenospehres and hollow glass microballoons as the fillers for creating syntactic foams. One of the major challenges is to minimize the fracture of hollow particles during filament manufacturing and 3D printing, which is addressed by parameter optimization during processing. Results show that the syntactic foam specimens are successfully printed and their properties are comparable to the injection molded specimens of the same compositions.

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Acknowledgments

Nikhil Gupta acknowledges the Office of Naval Research grant N00014-10-1-0988 grant with Dr. Yapa D. Rajapakse as the program manager. Mrityunjay Doddamani acknowledges Department of Science and Technology, India, grant DST/TSG/AMT/2015/394/G and Visiting Scientist Fellowship grant VSP 17-7-001 by the U.S. Office of Naval research – Global (Program manager: Dr. Ramesh Kolar) to visit NYU for part of this work. The views expressed in this work are of authors, not of funding agency. Riptide Autonomous Solutions (www.riptideas.com) is thanked for providing designs and useful discussions.

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Authors and Affiliations

  1. Composite Materials and Mechanics Laboratory, Mechanical and Aerospace Engineering Department, New York University, Tandon School of Engineering, Brooklyn, NY, USA

    Nikhil Gupta

  2. Advanced Manufacturing Laboratory, Department of Mechanical Engineering, National Institute of Technology Karnataka, Surathkal, Karnataka, India

    Mrityunjay Doddamani

Authors
  1. Nikhil Gupta
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  2. Mrityunjay Doddamani
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Correspondence to Nikhil Gupta .

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  1. Department of Aerospace Engineering, University of Maryland, College Park, College Park, MD, USA

    Sung W. Lee

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Gupta, N., Doddamani, M. (2020). 3D Printing of Syntactic Foams for Marine Applications. In: Lee, S. (eds) Advances in Thick Section Composite and Sandwich Structures. Springer, Cham. https://doi.org/10.1007/978-3-030-31065-3_14

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