Abstract: A method, material composition and apparatus for forming a three-dimensional structure using single part epoxy resins via electromagnetic induction heating. The method includes making a base matrix phase containing an epoxy resin and a latent curing agent with magneto-sensitive particles to obtain an electromagnetic (EM) phase. The mixture is transferred to a molding vessel having an electromagnetic induction heater positioned a first distance away from a top surface of the EM resin system and cured with the electromagnetic induction heater to form a three-dimensional structure.

Abstract: An additive manufacturing system based on electromagnetic induction heating is proposed for making three dimensional structures using thermosets. The additive manufacturing system that includes a resin bath containing an electromagnetically sensitive resin liquid, a support platform having an adjustable support platform height such that the support platform can be reversibly submerged in an electromagnetically sensitive resin liquid contained in the resin bath and a support platform adjustment motor connected to the support platform. The system further includes a movable head positioned above the support platform and including an electromagnetic radiation generating device, a head adjustment motor connected to the movable head and configured to adjust a position of the movable head, and a controller configured to control the support platform and the position of the movable head.

Abstract: A method is provided for determining optimal values of significant process parameters in an additive manufacturing (AM) process for printing a part from a specified process material. The method involves defining a set of target output material properties to be optimized and identifying an initial set of process parameters pertaining to the AM process. The method broadly comprises a screening phase and an optimization phase. The screening phase involves generating and executing a first experiment design, and determining, based on a first output response, a subset of significant process parameters that affect the target output material properties. The optimization phase involves generating and executing a second experiment design, and determining, based on a second output response, optimal values for the significant process parameters that maximize or minimize the target output material properties.

Abstract: A method is provided for determining optimal values of significant process parameters in an additive manufacturing (AM) process for printing a part from a specified process material. The method involves defining a set of target output material properties to be optimized and identifying an initial set of process parameters pertaining to the AM process. The method broadly comprises a screening phase and an optimization phase. The screening phase involves generating and executing a first experiment design, and determining, based on a first output response, a subset of significant process parameters that affect the target output material properties. The optimization phase involves generating and executing a second experiment design, and determining, based on a second output response, optimal values for the significant process parameters that maximize or minimize the target output material properties.