Abstract: An out-of-oven system for free-form fabrication of continuous carbon fiber composites includes a dielectric barrier discharge (DBD) applicator configured to create an electric field proximal to the continuous carbon fiber composite. The DBD applicator includes a first electrode disposed within a dielectric barrier, and a second electrode spaced apart from the first electrode. The first and second electrodes are configured to allow the continuous carbon fiber composite to pass therebetween to cure the continuous carbon fiber composite. The system uses Joule heating to cure the continuous carbon fiber composite.

Abstract: Provided herein is a method for repairing a composite material, a layup manufacturing process of a composite and a system for manufacturing a 3-dimensional composite part. The method, process and system all utilize a dielectric barrier discharge applicator to generate a plasma to cure an epoxy material to bond a patch to a composite material or to bond two or more layers of composite material together in a 3-dimensional shape to form a composite part.

Abstract: Processes and systems for electrochemical exfoliation that use a compression reactor and, more particularly, to processes and systems for electrochemical exfoliation of planar parent materials, such as graphite. A reactor for electrochemical exfoliation may include a container configured to hold an electrolyte solution. The reactor may further include a porous chamber, wherein the porous chamber is configured to hold a parent material in fluid communication with the electrolyte solution. The reactor may further include a pressure source positioned to apply a pressure along a length of the porous chamber to thereby compress the parent material in the porous chamber. The reactor may further include a first counter electrode. The reactor may further include a working electrode. The reactor may further include an electrical power source in electrical communication with the first counter electrode and the working electrode.

Abstract: A method is provided for bonding substrates having dissimilar coefficients of thermal expansion, using a thermoset adhesive. The method involves a pre-cure step using radio-frequency energy, followed by a heat-curing step.

Abstract: A microwave-induced heating of CNT filled (or coated) polymer composites for enhancing inter-bead diffusive bonding of fused filament fabricated parts. The technique incorporates microwave absorbing nanomaterials (carbon nanotubes (CNTs)) onto the surface or throughout the volume of 3D printer polymer filament to increase the inter-bead bond strength following a post microwave irradiation treatment and/or in-situ focused microwave beam during printing. The overall strength of the final 3D printed part will be dramatically increased and the isotropic mechanical properties of fused filament part will approach or exceed conventionally manufactured counterparts.

Abstract: In an embodiment, the present disclosure pertains to a method of direct ink writing (DIW). In general, the method includes extruding a resin from a print head, applying radio frequency (RF) heating to the resin, and inducing partial curing of the extruded resin layer-by-layer to thereby form a self-supporting structure. In an additional embodiment, the present disclosure pertains to a system for DIW. In some embodiments, the system includes a print head operable to extrude a resin from a nozzle and an RF applicator.

Abstract: Methods and reactors for electrochemically expanding a parent material and expanded parent materials are described. Current methods of expanding parent materials incompletely-expand parent material, requiring expensive and time-consuming separation of expanded parent material from unexpanded parent materials. This problem is addressed by the methods and reactor for electrochemically expanding a parent material described herein, which during operation maintain electrical connectivity between the parent material and an electrical power source. The resulting materials described herein have a greater proportion of expanded parent material relative to unexpanded parent material compared to those made according to others methods.

Abstract: A method for chemical production includes applying electromagnetic heating to a composition that includes a catalytic component and an electromagnetic susceptor. Responsive to application of radio frequency energy, the electromagnetic susceptor causes the catalytic component to become heated. The heated electromagnetic susceptor and catalytic component interact with a chemical to form a product.

Abstract: A method of electrochemical exfoliation, may include: electrochemically exfoliating a parent material comprising coke, wherein the electrochemically exfoliating comprises introducing the parent material into a porous chamber, applying pressure to the porous chamber to thereby compress the parent material in the porous chamber, and applying a potential bias to the parent material while at least a portion of the parent material is in contact with an electrolyte solution to produce a mixture of exfoliated material and unexfoliated parent material, wherein the exfoliated material comprises exfoliated graphene; and separating at least a portion of the exfoliated material from the unexfoliated parent material.

Abstract: Methods and reactors for electrochemically expanding a parent material and expanded parent materials are described. Current methods of expanding parent materials incompletely-expand parent material, requiring expensive and time-consuming separation of expanded parent material from unexpanded parent materials. This problem is addressed by the methods and reactor for electrochemically expanding a parent material described herein, which during operation maintain electrical connectivity between the parent material and an electrical power source. The resulting materials described herein have a greater proportion of expanded parent material relative to unexpanded parent material compared to those made according to others methods.

Abstract: Processes and systems for electrochemical exfoliation that use a compression reactor and, more particularly, to processes and systems for electrochemical exfoliation of planar parent materials, such as graphite. A reactor for electrochemical exfoliation may include a container configured to hold an electrolyte solution. The reactor may further include a porous chamber, wherein the porous chamber is configured to hold a parent material in fluid communication with the electrolyte solution. The reactor may further include a pressure source positioned to apply a pressure along a length of the porous chamber to thereby compress the parent material in the porous chamber. The reactor may further include a first counter electrode. The reactor may further include a working electrode. The reactor may further include an electrical power source in electrical communication with the first counter electrode and the working electrode.

Abstract: Methods and reactors for electrochemically expanding a parent material and expanded parent materials are described. Current methods of expanding parent materials incompletely-expand parent material, requiring expensive and time-consuming separation of expanded parent material from unexpanded parent materials. This problem is addressed by the methods and reactor for electrochemically expanding a parent material described herein, which during operation maintain electrical connectivity between the parent material and an electrical power source. The resulting materials described herein have a greater proportion of expanded parent material relative to unexpanded parent material compared to those made according to others methods.

Abstract: A method of fabrication processing a pre-preg material includes applying electromagnetic heating to a composition including a fiber and a resin. The electromagnetic heating is conducted with at least one fringing field capacitor utilizing radio frequency (RF) alternating current (AC) and controlling cross-linking of the resin in the composition via the electromagnetic heating.

Abstract: A non-contact method of joining two components via direct heating of a thermoset adhesive includes applying the thermoset adhesive to at least a first component of the two components. The thermoset adhesive includes a susceptor to reacts in the presence of an electromagnetic field. The method includes placing the first component and a second component of the two components in proximity to an electromagnetic field. In some aspects, the method includes placing the first and second components in proximity to an electromagnetic field of a capacitor. The susceptor interacts with the electromagnetic field to heat the thermoset adhesive via resistive heating. In some aspects, a method of direct-contact heating of the thermoset adhesive includes attaching electrodes to a film comprising the adhesive. The components being joined together are not directly heated by the electromagnetic field, and as a result experience much lower temperatures than the thermoset adhesive.

Abstract: The invention relates to additive manufacturing systems and methods using thermally cross-linkable materials. The thermally cross-linkable material includes at least one thermally cross-linkable polymeric material and an amount of at least one electromagnetic energy susceptor therein. A system with at least one print head and an electromagnetic energy generator is provided to produce electromagnetic energy in the area of the thermally cross-linkable material after being dispensed from the print head. This causes heating of the electromagnetic energy susceptor to cause curing of the thermally cross-linkable material.

Abstract: A microwave-induced heating of CNT filled (or coated) polymer composites for enhancing inter-bead diffusive bonding of fused filament fabricated parts. The technique incorporates microwave absorbing nanomaterials (carbon nanotubes (CNTs)) onto the surface or throughout the volume of 3D printer polymer filament to increase the inter-bead bond strength following a post microwave irradiation treatment and/or in-situ focused microwave beam during printing. The overall strength of the final 3D printed part will be dramatically increased and the isotropic mechanical properties of fused filament part will approach or exceed conventionally manufactured counterparts.

Abstract: A electromagnetic wave-induced heating of CNT filled (or coated) polymer composites for enhancing inter-bead diffusive bonding of fused filament fabricated parts. The technique incorporates electromagnetic wave absorbing nanomaterials (carbon nanotubes (CNTs)) onto the surface or throughout the volume of 3D printer polymer filament to increase the inter-bead bond strength following a post electromagnetic wave irradiation treatment and/or in-situ focused electromagnetic beam during printing. The overall strength of the final 3D printed part will be dramatically increased and the isotropic mechanical properties of fused filament part will approach or exceed conventionally manufactured counterparts.

Abstract: Methods and reactors for electrochemically expanding a parent material and expanded parent materials are described. Current methods of expanding parent materials incompletely-expand parent material, requiring expensive and time-consuming separation of expanded parent material from unexpanded parent materials. This problem is addressed by the methods and reactor for electrochemically expanding a parent material described herein, which during operation maintain electrical connectivity between the parent material and an electrical power source. The resulting materials described herein have a greater proportion of expanded parent material relative to unexpanded parent material compared to those made according to others methods.

Abstract: Methods for dissolving carbon materials such as, for example, graphite, graphite oxide, oxidized graphene nanoribbons and reduced graphene nanoribbons in a solvent containing at least one superacid are described herein. Both isotropic and liquid crystalline solutions can be produced, depending on the concentration of the carbon material The superacid solutions can be formed into articles such as, for example, fibers and films, mixed with other materials such as, for example, polymers, or used for functionalization of the carbon material. The superacid results in exfoliation of the carbon material to produce individual particles of the carbon material. In some embodiments, graphite or graphite oxide is dissolved in a solvent containing at least one superacid to form graphene or graphene oxide, which can be subsequently isolated. In some embodiments, liquid crystalline solutions of oxidized graphene nanoribbons in water are also described.

Abstract: A microwave-induced heating of CNT filled (or coated) polymer composites for enhancing inter-bead diffusive bonding of fused filament fabricated parts. The technique incorporates microwave absorbing nanomaterials (carbon nanotubes (CNTs)) onto the surface or throughout the volume of 3D printer polymer filament to increase the inter-bead bond strength following a post microwave irradiation treatment and/or in-situ focused microwave beam during printing. The overall strength of the final 3D printed part will be dramatically increased and the isotropic mechanical properties of fused filament part will approach or exceed conventionally manufactured counterparts.