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The first phase of the project established the performance of some commercially available polymer compositions deposited with the BAAM system. Carbon fiber reinforced ABS demonstrated a tensile strength of nearly 10 ksi, which is sufficient for a number of low temperature tooling applications. | OSTI.GOV

Screw extrusion-based large-format additive manufacturing is a rapidly growing manufacturing solution for CFRP molds for the aerospace and motorsport industry. It ensures significant weight and time savings compared with the conventional technologies. The massive tooling part was 3D printed over the course of 30 hours on ORNLs Big Area Additive Manufacturing (BAAM) machine, resulting in a part that measures 17.5 feet long, 5.5 feet wide and 1.5 feet tall and weighs about 1,650 pounds.

Thats roughly the length of a large SUV. The BAAM system works by feeding material, often a combination of ABS plastic and carbon fiber pellets, from a ... Carbon fiber (CF)-reinforced thermoplastic composites have been widely used in different structural applications due to their superior thermal and mechanical properties.

In this paper, the fracture behavior of neat acrylonitrile butadiene styrene (ABS) and short carbon fiber-reinforced ABS (CF/ABS) fabricated by LAAM is compared and analyzed by evaluating their energy release rate and fracture mechanisms. Using new materials (carbon fiber-reinforced polymers), new processes (extruders) and controls, the team enabled an out-of-oven additive process that eliminated size constraints, enabled processing rates 500 times faster and build volumes 100 times larger than those of state-of-the-art commercial printing systemswith less material and ... Big Area Additive Manufacturing (BAAM) is an extrusion-based AM technique developed at Oak Ridge National Laboratory in conjunction with Cincinnati Inc.

BAAM can build complex structures that are as large as 6 m long, 2.4 m wide, and 1.8 m tall, which is roughly 10 times larger than the commercial AM systems such as those used in fused The ... The Big Area Additive Manufacturing (BAAM) system located at Oak Ridge National Laboratory s (ORNL) Manufacturing Demonstration Facility (MDF) has been used to manufacture a new generation of in-autoclave tools that can be used to fabricate various aerospace composite parts. This project represented the first rigorous testing of Techmer materials on the BAAM system and proof that the carbon fiber reinforced ABS could provide sufficient strength for initial tooling and concept car applications.

Large-format additive manufacturing (LFAM) is an enabling manufacturing technology capable of producing large parts with highly complex geometries for a wide variety of applications, including automotive, infrastructure/construction, and aerospace mold and tooling.