Composite materials printed with ultrasonic additive manufacturing system

According to the university, the technology will soon enable a much greater range of items to be 3D printed at home on a small budget.

The study published in Smart Materials and Structures creates and demonstrates a novel method in which ultrasonic waves are used to position reinforcement fibres as part of the 3D printing process. The fibres are formed into a microscopic reinforcement framework that gives the material strength. This microstructure is then set in place using a focused laser beam, which locally cures the epoxy resin and then prints the object.

To achieve this the research team mounted a switchable, focused laser module on the carriage of a standard three-axis 3D printing stage, above the new ultrasonic alignment apparatus.

Tom Llewellyn-Jones, a PhD student in advanced composites who developed the system, said: "We have demonstrated that our ultrasonic system can be added cheaply to an off-the-shelf 3D printer, which then turns it into a composite printer."