3D Printing of Impact-Resistant Composites with Helicoidal Fibre Reinforcements

Opportunity

With industries prioritising lightweight, high-performance materials, the demand for 3D printing fibre-reinforced polymers continues to rise to fulfil growing customer demands and regulatory needs. Engineering composites offer benefits such as improved fuel efficiency in vehicles and enhanced durability in aerospace and defence applications. However, conventional composite struggles with achieving high fibre concentration, shaping flexibility and impact resistance. This innovation addresses these challenges, offering scalable, low-cost and highly formable composites with exceptional mechanical performance. The global high performance composites market, valued at $33 billion in 2022, is projected to reach $59.4 billion by 2032, growing at a CAGR of 6.2%.

Technology  

This invention uses ink direct writing (DIW) to fabricate helicoidal fibre-reinforced composites with superior mechanical properties. In DIW, a viscous ink containing microfibres, exceeding 50 wt% concentration, is extruded from a small nozzle and deposited layer-by-layer, aligning fibres along the printing direction. By programming the printing angle at each layer, the fibres form a helicoidal microfibre arrangement, enhancing impact resistance and preventing delamination. Unlike conventional methods, this process operates at room temperature and does not need high-temperature treatment. The resulting 3D printed impact-resistant composites exhibit lightweight, low porosity, high strength and high impact resistance properties, making them ideal for high-performance composites in aerospace, lightweight automotive applications and 3D printable composites for defence and sports. The polymer matrix can also be replaced with recyclable and sustainable thermoplastics for eco-friendly manufacturing.  

Figure 1: 3D printing with helicoidal microfibre arrangement. 

Applications & Advantages

Applications:  

• Aerospace: Structural components benefiting from high strength and impact resistance.
• Automotive: Lightweight composites for improved fuel efficiency.
• Defence and sports: Durable and high-performance materials for protective equipment and advanced gear.

Advantages: 

• High impact resistance with 140% greater energy absorption than unidirectional composites.
• Scalable and cost-effective direct ink writing process.
• Lightweight, low porosity and high-strength composites with superior mechanical performance.
• Room temperature processing without high-temperature curing requirements.
• Sustainable alternative — polymer matrix can be replaced with recyclable thermoplastics.