3D-printed resistive carbon-fiber-reinforced sensors for monitoring the resin frontal flow during composite manufacturing

Abstract

Abstract In this paper, novel resin frontal flow monitoring electrically resistive sensors made of reinforced continuous carbon fibers and manufactured by composite additive manufacturing (AM) are examined. For such manufacture, two adjacent and parallel fiber yarns made with carbon-fiber embedded in the polymer matrix were deposited by using a 3D printer system. These flexible flow sensors were made of two nylon wall layers, had a fixed separating distance between conductive carbon filament and were printed on nylon peel-ply. Thickness of the nylon walls and filaments separating distance were optimised and tested with different vacuum-assisted resin infusion (VARI) experimental trials by measuring the voltage drop between their filaments edges in order to monitor properly the resin frontal flow. It is concluded that the sensing configuration presented here as a removable fiber/polymer unit could be used for obtaining high-quality composites by monitoring the resin frontal flow.