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MIL OSI Translation. Region: Russian Federation –

Source: Peter the Great St Petersburg Polytechnic University – Peter the Great St Petersburg Polytechnic University – Peter the Great St Petersburg Polytechnic University.

For the first time in Russia, specialists of the Advanced Engineering School “Digital Engineering” of Polytechnic have developed a pilot technology for the production of filaments (a consumable material in the form of filament used for 3D printing) made of continuous carbon fiber based on thermoplastics. Filament has unique physical and mechanical properties compared to other materials used in 3D printing and is used primarily in the rocket and space and aviation industries, as well as in the engine industry. The development was commissioned by the Composite Division of Rosatom State Corporation.

Carbon fiber has high strength and stiffness while being very lightweight. This allows it to be used to create strong and lightweight parts that can withstand heavy loads. At the same time, carbon fiber is resistant to high temperatures or chemical attack. Filaments made of continuous carbon fiber and high-temperature polymer of the polyaryl ketone group are used for 3D printing in special printers using layer-by-layer deposition technology (FDM and FFF).

Composite materials (including filaments) from continuous carbon fiber are currently produced by several countries: USA, Switzerland and China. This material is strategic due to the specifics of its use and is practically not exported. Employees of SPbPU NSP “Digital Engineering” have developed not only the technology of manufacturing filaments from continuous carbon fiber based on thermoplastics, but also manufactured a laboratory unit for its production with a capacity of 500 meters of filament per hour. This plant is commissioned in the fall of 2023 at the Composite Division of Rosatom and is now being used to produce pilot batches of materials.

For more than 10 years our team has been developing technologies for impregnation of carbon fibers with thermoplastic polymers from the group of polyaryletherketones. It is very important for us that the results of our laborious work will soon be implemented in industrial production. The solution of the problem of production of domestic filaments from this material is one more step towards achieving technological sovereignty for our country, – Ilya Kobykhno, Candidate of Technical Sciences, Head of the Laboratory “Polymer Composite Materials” of the SPbPU NSPP commented on the importance of the work done.

The production of filaments from continuous carbon fiber and high-temperature polymers is based on the technology of suspension impregnation. This approach provides obtaining unidirectional thermoplastic prepregs (carbon fibers impregnated with polymer) with the least fiber damage and uniform polymer distribution over the entire cross-section, which is most important for solving problems associated with ensuring maximum strength properties.

The development of our own technology for the production of continuous carbon fiber composites based on thermoplastics is a very important task in strategic terms. Russia is one of the few countries which produces engines. And the application of such a high-quality material by its properties, we are sure, first of all, will be especially demanded in the domestic engine building for the production of new generation engines, – Anton Shumakov, the director of the project “Thermoplastics” of the Composite Division of Rosatom commented on the development potential.

Currently, specialists of the Advanced Engineering School of SPbPU are developing technology and a pilot plant for filament production with a capacity of 12,000 meters per hour. The developed pilot plant will enable simultaneous production of 40 filaments from continuous carbon fiber. The process of manufacturing and debugging of operating modes of modules and units of the plant is already underway. In the summer of 2024, the pilot line will be put into operation at the production site of Rosatom’s Composite Division.

Please note; This information is raw content directly from the source of the information. It is accurate to what the source states and does not reflect the position of MIL-OSI or its customers.

Please note; This information is raw content directly from the information source. It is accurate to what the source is stating and does not reflect the position of MIL-OSI or its clients.

EDITOR’S NOTE: This article is a translation. Apologies should the grammar and or sentence structure not be perfect.

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