Kunal Masania

Kunal Masania
Delft University of Technology | TU · Aerospace Structures and Materials (ASM)

Professor

About

104
Publications
40,871
Reads
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2,308
Citations
Introduction
We develop hierarchical bioinspired materials with contradicting properties (e.g. tough and strong, stiff and dissipative). Using 3D printing, we exploit directed- & self-assembly of natural or carbon-based materials across multiple length scales in order to study the role of anisotropy and porosity and apply these microstructural designs to large structures.
Additional affiliations
January 2020 - present
Delft University of Technology
Position
  • Professor (Associate)
October 2015 - December 2019
ETH Zurich
Position
  • Senior Researcher
January 2011 - September 2015
University of Applied Sciences and Arts Northwestern Switzerland
Position
  • Senior Researcher
Education
September 2006 - June 2010
Imperial College London
Field of study
  • Mechanics of materials

Publications

Publications (104)
Article
Full-text available
Levitation offers extreme isolation of mechanical systems from their environment, while enabling unconstrained high‐precision translation and rotation of objects. Diamagnetic levitation is one of the most attractive levitation schemes because it allows stable levitation at room temperature without the need for a continuous power supply. However, di...
Preprint
Full-text available
Levitation offers extreme isolation of mechanical systems from their environment, while enabling unconstrained high-precision translation and rotation of objects. Diamagnetic levitation is one of the most attractive levitation schemes, because it allows stable levitation at room temperature without the need for a continuous power supply. However, d...
Article
Full-text available
Three‐dimensional printing is a powerful manufacturing technology for shaping materials into complex structures. While the palette of printable materials continues to expand, the rheological and chemical requisites for printing are not always easy to fulfill. Here, we report a universal manufacturing platform for shaping materials into intricate ge...
Article
Full-text available
Biological materials such as nacre have evolved microstructural design principles that result in outstanding mechanical properties. While nacre’s design concepts have led to bio-inspired materials with enhanced fracture toughness, the microstructural features underlying the remarkable damping properties of this biological material have not yet been...
Cover Page
3D Printing In article number 2203878, Kunal Masania, André R. Studart, and co‐workers present a light 3D‐printable salt ink as a sacrificial template for the shaping of complex materials. This offers unprecedented shaping freedom to hard‐to‐print materials such as magnesium for resorbable bone implants, or polystyrene and polycaprolactone for 3D c...
Article
Ultra-high angular resolution in astronomy has always been an important vehicle for making fundamental discoveries. Recent results in direct imaging of the vicinity of the supermassive black hole in the nucleus of the radio galaxy M87 by the millimeter VLBI system Event Horizon Telescope and various pioneering results of the Space VLBI mission Radi...
Article
Plant-derived natural fibres hold great potential as renewable and sustainable reinforcing elements in structural composites. However, a broader use of natural fibre composites requires further improvements in their mechanical properties, to reach performance comparable to carbon fibre-reinforced polymers. In this study, we exploit discontinuous ca...
Preprint
Full-text available
Ultra-high angular resolution in astronomy has always been an important vehicle for making fundamental discoveries. Recent results in direct imaging of the vicinity of the supermassive black hole in the nucleus of the radio galaxy M87 by the millimeter VLBI system Event Horizon Telescope and various pioneering results of the Space VLBI mission Radi...
Preprint
Full-text available
Biological living materials, such as animal bones and plant stems, are able to self-heal, regenerate, adapt and make decisions under environmental pressures. Despite recent successful efforts to imbue synthetic materials with some of these remarkable functionalities, many emerging properties of complex adaptive systems found in biology remain unexp...
Article
Full-text available
Fiber‐reinforced polymers are widely used as lightweight materials in aircraft, automobiles, wind turbine blades, and sports products. Despite the beneficial weight reduction achieved in such applications, these composites often suffer from poor recyclability and limited geometries. 3D printing of liquid crystal polymers into complex‐shaped all‐fib...
Article
Full-text available
Porous materials are relevant for a broad range of technologies from catalysis and filtration, to tissue engineering and lightweight structures. Controlling the porosity of these materials over multiple length scales often leads to enticing new functionalities and higher efficiency but has been limited by manufacturing challenges and the poor under...
Article
Full-text available
Monolithic aerogels composed of crystalline nanoparticles enable photocatalysis in three dimensions, but they suffer from low mechanical stability and it is difficult to produce them with complex geometries. Here, an approach to control the geometry of the photocatalysts to optimize their photocatalytic performance by introducing carefully designed...
Article
Full-text available
Vat photopolymerization 3D printing provides new opportunities for the fabrication of tissue scaffolds and medical devices. However, for the manufacturing of biodegradable elastomers, it usually requires the use of organic solvents to dissolve the solid photoinitators and achieve low resin viscosity, making this process environmentally unfriendly a...
Preprint
Full-text available
Porous materials are relevant for a broad range of technologies from catalysis and filtration, to tissue engineering and lightweight structures. Controlling the porosity of these materials over multiple length scales often leads to enticing new functionalities and higher efficiency but has been limited by manufacturing challenges and the poor under...
Article
The out-of-plane permeability of two glass fibre fabrics was measured by 26 institutions using silicone oil as a test fluid. Participants in this study were free to select the test procedure, specimen dimensions and data analysis method, provided that testing was carried out at three target fibre volume fractions, 46 %, 50 % and 54 %. While results...
Article
Full-text available
Central airway obstruction is a life-threatening disorder causing a high physical and psychological burden to patients. Standard-of-care airway stents are silicone tubes, which provide immediate relief but are prone to migration. Thus, they require additional surgeries to be removed, which may cause tissue damage. Customized bioresorbable airway st...
Preprint
p>Vat photopolymerization 3D printing provides new opportunities for the fabrication of tissue scaffolds and medical devices. However, it usually requires the use of organic solvents or diluents to dissolve the solid photoinitators, making this process environmentally unfriendly, and not optimal for biomedical applications. Here, we report bio...
Article
This paper reports the results of an international benchmark exercise on the measurement of fibre bed compaction behaviour. The aim was to identify aspects of the test method critical to obtain reliable results and to arrive at a recommended test procedure for fibre bed compaction measurements. A glass fibre 2/2 twill weave and a biaxial (±45°) gla...
Article
Full-text available
The effect of ply thickness on the notch sensitivity and bearing properties on carbon fibre reinforced polymer composites and their hybrid laminates with steel foils were studied. Laminates with ply thicknesses of 0.3 mm and 0.03 mm comprising of CFRP and hybrid laminates were manufactured and characterized using tension, open hole tension and doub...
Preprint
Full-text available
Central airway obstruction is a life-threatening disorder causing a high physical and psychological burden to patients due to severe breathlessness and impaired quality of life. Standard-of-care airway stents are silicone tubes, which cause immediate relief, but are prone to migration, especially in growing patients, and require additional surgerie...
Article
Structural materials combining high stiffness and damping capabilities are in high demand for passive damping applications in vibration control, precision manufacturing and resilient buildings. However, the development of enhanced passive damping materials with high stiffness at low weight has been hindered by the mutually excluding nature of these...
Cover Page
Full-text available
Three-dimensional printing of multicomponent glasses using phase-separating resins cover page
Article
Full-text available
The digital fabrication of oxide glasses by three-dimensional (3D) printing represents a major paradigm shift in the way glasses are designed and manufactured, opening opportunities to explore functionalities inaccessible by current technologies. The few enticing examples of 3D printed glasses are limited in their chemical compositions and suffer f...
Article
Passive spanwise bending shape-adaption has the potential to increase the efficiency and manoeuvrability of vehicles with wing-like structures. By utilisation of compression flange buckling, the in-plane stiffness can be tuned to design beams with contrasting pre-buckling and post-buckling bending stiffness. The investigated concept is experimental...
Preprint
Passive spanwise bending shape-adaption has the potential to increase the efficiency and manoeuvrability of vehicles with wing-like structures. By utilisation of compression flange buckling, the in-plane stiffness can be tuned to design beams with contrasting pre-buckling and post-buckling bending stiffness. The investigated concept is experimental...
Article
Full-text available
DNA storage offers substantial information density1,2,3,4,5,6,7 and exceptional half-life³. We devised a ‘DNA-of-things’ (DoT) storage architecture to produce materials with immutable memory. In a DoT framework, DNA molecules record the data, and these molecules are then encapsulated in nanometer silica beads⁸, which are fused into various material...
Technical Report
SI for DNA-of-things storage architecture to create materials with embedded memory
Data
SI video of A DNA-of-things storage architecture to create materials with embedded memory
Technical Report
SI for Three-dimensional printing of multicomponent glasses using phase-separating resins
Article
Wood is increasingly considered in sustainable structural materials development due to its hierarchical structure, including an oriented reinforcing cellulose phase combined with carbon-capturing and renewability. Top-down manufacturing techniques provide direct access to this hierarchical cellulose scaffold for use in new functional materials. For...
Conference Paper
Full-text available
The development of sustainable materials from renewable resources is one of the key challenges in today's materials science. Wood has great potential to play an important role in future materials advancement due to its excellent mechanical properties and high abundance. In this regard, two novel concepts for the development of high-performance wood...
Article
Wood is increasingly considered in sustainable structural materials development due to its hierarchical structure, including an oriented reinforcing cellulose phase combined with carbon-capturing and renewability. Top-down manufacturing techniques provide direct access to this hierarchical cellulose scaffold for use in new functional materials. For...
Article
Full-text available
Porosity is an essential feature in a wide range of applications that combine light weight with high surface area and tunable density. Porous materials can be easily prepared with a vast variety of chemistries using the salt-leaching technique. However, this templating approach has so far been limited to the fabrication of structures with random po...
Article
Full-text available
In article number 1903783, Martina Cihova, André R. Studart, Jörg F. Löffler, and co‐workers present a rheologically engineered salt paste as a sacrificial 3D‐printing ink for the structuring of porous magnesium (Mg) scaffolds. The ability to structure the porosity in Mg is highly attractive for its use as a resorbable bone replacement because it e...
Technical Report
Porosity is an essential feature in a wide range of applications that combine light weight with high surface area and tunable density. Porous materials can be easily prepared with a vast variety of chemistries using the salt‐leaching technique. However, this templating approach has so far been limited to the fabrication of structures with random po...
Article
Natural materials such as wood exhibit high mechanical properties through cellulose structured at multiple length scales and embedded in a matrix of similar chemical structure. These hierarchical materials have inspired the design of lightweight composites composed of naturally occurring polymers. However, the close proximity of melt and decomposit...
Article
Full-text available
Elegant design principles in biological materials such as stiffness gradients or sophisticated interfaces provide ingenious solutions for an efficient improvement of their mechanical properties. When materials such as wood are directly used in high‐performance applications, it is not possible to entirely profit from these optimizations because stif...
Article
To reduce the cycle time of structural, automotive thermoplastic composites, we investigated the potential of direct thermoplastic melt impregnation of glass fabrics using an injection moulding process. At the high pressures that occur during the process, the effect of the fabric architecture on the impregnation, compaction, volume fraction and per...
Article
Natural fibre (NF) reinforced composites offer high specific mechanical properties and are an ecological alternative to synthetic fibre-reinforced composites. While having great potential, their use today is limited to non-structural applications, mostly with epoxy or polypropylene matrices. This work studies suitable high-performance thermoplastic...
Article
Full-text available
Reinforced polymer‐based composites are attractive lightweight materials for aircrafts, automobiles, and turbine blades, but still show strength and fracture toughness lower than traditional metals. An interesting approach to address this issue is to fabricate composites with structural features that absorb part of the elastic energy stored in the...
Article
The nacreous layer of mollusk shells holds design concepts that can effectively enhance the fracture resistance of lightweight brittle materials. Mineral bridges are known to increase the fracture resistance of nacre-inspired materials, but their role is difficult to quantify due to the lack of experimental systems where only this parameter is cont...
Article
Full-text available
Fibre-reinforced polymer structures are often used when stiff lightweight materials are required, such as in aircraft, vehicles and biomedical implants. Despite their very high stiffness and strength1, such lightweight materials require energy- and labour-intensive fabrication processes2, exhibit typically brittle fracture and are difficult to shap...
Article
Full-text available
To evaluate compatibility between a substrate and a thermoplastic polymer, the established methodology is to estimate their surface composition in terms of surface energy components, utilizing the results of contact angle measurements of probe liquids onto substrate and polymer surfaces at room temperature. Using this methodology, polymer surfaces...
Article
Fast-cure epoxy systems are used for the mass production of composite parts with cycle times in the minute range. One of the major difficulties observed when processing fast-cure resins is their strong exothermic reaction during cure. This may result in a significant temperature overshoot and large temperature gradients over the thickness, and ther...
Conference Paper
Full-text available
Carbon fibre reinforced polymer (CFRP) parts can be functionalized with thermoplastic surfaces in order to be assembled through welding as a cost-efficient alternative to traditional joining techniques such as mechanical fastening or adhesive bonding. In the process of functionalizing the CFRP, curing an epoxy resin in the presence of a thermoplast...
Article
An epoxy resin, cured with an anhydride, has been modified by the addition of silica nanoparticles. The particles were introduced via a sol-gel technique which gave a very well dispersed phase of nanosilica particles, which were about 20 nm in diameter, in the thermosetting epoxy polymer matrix. The glass transition temperature of the epoxy polymer...
Conference Paper
Full-text available
Structural materials such as metals and fibre-reinforced plastics are stiff engineering materials used in many industrial fields. However, their high stiffness leads usually to the inability to dissipate energy via vibration damping. Contrarily, compliant materials such as rubbers and soft polymers exhibit an excellent damping behaviour, but lack i...
Article
The core – sheath interfacial interactions in a bicomponent thermoplastic filament have been analyzed by means of an adapted micro-mechanical approach for interfacial pull-out. The method relies on a specimen preparation procedure that selectively removes a segment of the sheath component while leaving the core intact. This adaptation of the classi...
Article
Full-text available
The increasing use of carbon fibre reinforced polymer (CFRP) composites in aviation and automotive industries has led to the adoption of automated production methods such as pultrusion or resin transfer moulding (RTM) for cost reduction in the production lightweight structures. These processes however, offer limited freedom to locally reinforce str...
Conference Paper
Full-text available
Thermoplastic matrix materials have advantages of fast processing, recyclability, high fracture toughness and offer alternative joining processes like welding. However, thermoplastic matrix materials have a higher viscosity than thermoset resins, which makes the impregnation of fabrics more difficult, especially at the high fibre volume fractions n...
Conference Paper
Full-text available
The importance of the interphase as the material part for transferring stress is widely recognized [1]; however, the wetting behaviour of molten polymers during composite manufacturing or how the interface is formed at high temperature between the molten thermoplastic and the hot fibre surface are yet to be studied in detail. The final mechanical p...
Article
To simultaneously address the lower toughness and the build-up of internal heat for fast-curing epoxy matrices, the influence of nominal 100 nm and 300 nm core-shell rubber (CSR) particles on the properties and rheo-kinetics were studied. The fracture energy was enhanced by a factor of 14.5, up to 2572 ± 84 J m⁻² with 14.5 wt% of the nominal 300 nm...
Article
The rheological properties of epoxy matrices and adhesives during cure are modelled in this work. Three epoxy-amine systems, designed for different applications with distinct curing behaviours, were investigated. Curing times ranged from a few seconds to upwards of 220 min depending on the cure temperature and formulation of the epoxy. The presente...
Article
The damping behaviour of continuous carbon fibre and flax fibre reinforced polymer (CFRP and FFRP) composites was studied by comparing angle-ply laminates. Using logarithmic decrement measurements, dynamic mechanical analysis and vibration beam measurements, the damping was described as the specific damping capacity ψ in order to compare data using...
Article
Full-text available
Bulk nacre-like composites with mineral nano-interconnectivity at the same length scale as in the biological material were produced using magnetic alignment and selective sintering techniques. These materials display stiffness and strength levels comparable to that of continuous fiber composites with the advantage of easier processability inherent...
Conference Paper
Full-text available
Fast-curing epoxies allow parts to be manufactured in minutes, but the curing is highly exo-thermic and the low thermal conductivity causes the properties vary through the thickness. The addition of silica or core-shell rubber nanoparticles reduces the exotherm, and improves the mechanical properties. Little toughening was obtained with silica nano...
Article
Full-text available
This article describes how the strong exothermic reaction of a fast-cure epoxy can be better controlled with the addition of non-reactive silica nanoparticles, further enhancing the benefits of a fast process, the toughness and the ability to understand the properties of thicker composite parts. F ast-cure epoxy systems are used for the mass produc...