Additive manufacturing of composite parts (ADDCOMP)

Additive manufacturing (AM), also widely recognized as 3D printing, is driving a significant shift in the use of materials for engineered parts. One of the key advancements in this field is the integration of short- and continuous-fiber-reinforced polymeric composites, which are increasingly being used as alternatives to traditional materials such as metals and polymers. This shift is not only expanding the possibilities for part design but also offering numerous performance and manufacturing benefits.

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Among the many advantages of AM-enabled composites is their superior corrosion resistance, making them ideal for use in challenging environmental conditions. Additionally, AM provides scalability, reducing lead times and allowing for faster prototyping and production. The enhanced strength-to-weight ratio of these materials leads to lighter, stronger parts, making them especially attractive for industries like maritime, energy, and defense. The ability to print with multiple materials at varying scales within a single process further enhances design flexibility, enabling more complex and optimized structures. As a result, composite AM value chain is poised to witness a transformative era in manufacturing, offering a versatile, sustainable, and cost-effective solution for creating high-performance parts.

Challenge

Despite the remarkable progress in the field of 3D printing for composite materials, several challenges remain that impede its full potential and widespread adoption. One of the main limitations is the absence of an agreed cohesive set of guidelines to standardize the build and print process. Another major hurdle is the relatively narrow range of materials and applications that can currently be used. This restricts the versatility of 3D printing for various industries and specialized needs. Moreover, achieving consistently high product quality with reproducibility remains a significant hurdle. Issues such as voids, inconsistent fiber orientations, and other defects can result in suboptimal performance, hamper long-term durability and apprehension towards adoption of the technology.  

Solution

In response to current challenges and inputs from our industrial partners, DNV is leading a collaborative effort aimed at increasing industry-wide acceptance of 3D printed composite parts. By bringing together key stakeholders, this joint industry project (JIP)- ADDCOMP - seeks to leverage available technologies to address critical issues such as reproducibility and maintaining consistently high product quality. A major focus will be on establishing clear directives for printing processes, including the use of both short- and continuous-fiber reinforcements, as well as developing solutions for multi-material printing.

The overarching goal of this initiative is to create a comprehensive set of technical guidelines that will de-risk the composite additive manufacturing value chain. These guidelines are designed to build confidence among manufacturers, designers, and end-users by ensuring that 3D printed composite parts meet the necessary performance and quality standards. The project will also include a thorough techno-economic assessment, comparing the efficiency and viability of metallic and composite parts in engineering applications, along with pilot case studies to gather insights and lessons learned during the development of these guidelines. Through this effort, DNV aims to pave the way for more widespread acceptance and integration of composite additive manufacturing, fostering innovation and growth in this rapidly evolving field.

Deliverables

• A project report that will establish a set of comprehensive guidelines aimed at updating the DNV-ST-B203 standard, ensuring that it reflects the latest advancements in 3D printing technologies for composite materials. This report will not only serve as a technical reference for the update but also lay the foundation for future recommended practices (RPs), designed to complement existing DNV documents and support the evolving needs of the industry. 
  
  
• A public whitepaper that delves into the benefits and challenges of using 3D printed composite parts in engineering applications, with a specific focus on the energy and maritime sectors. This whitepaper will provide valuable insights into how additive manufacturing can enhance performance and sustainability within these industries, while also addressing the key obstacles that need to be tackled for successful implementation. These resources aim to guide industry stakeholders toward a more informed and confident adoption of composite additive manufacturing technologies.

Schedule

The project is planned to be completed in 18-24 months with the kick-off planned in Q4 2024. 

Budget and participation costs

The project budget is 4.5mNOK. Each party will contribute up to the agreed maximum amount e.g. large companies 600kNOK, medium 300kNOK and small 150kNOK

9/24/2024 8:34:00 AM