The optimization and evolution of high temperature, inorganic and ceramic materials is a key focus area for development in additive manufacturing (AM). The AM production of carbon/carbon (C/C) composites remains relatively underexplored. This work will discuss formulation and direct ink writing (DIW) optimization of phenolic resin/carbon fiber inks into C/C composites. We exploit recent advances in the DIW of ceramics, including the printing of preceramic polymers and preceramic polymer-based slurries containing particles or fibers. While the DIW process gives control over macroscopic component form factor, it additionally facilitates the alignment of high aspect ratio fillers (e.g., carbon fiber) which influences material properties. Relationships between ink formulation, rheology, and printability will be discussed as well as the process of carbon-conversion, and the effect of alignment on C/C composite properties.

Direct ink writing of phenolic resin-based inks into carbon/carbon composites

ACS Spring 2022

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