Vlastimil Kunc

• Ph.D.
• R&D Staff at Oak Ridge National Laboratory

Effective lightning strike protection for critical aerospace and wind applications requires high electrical conductivity to dissipate current efficiently. However, polymer matrix composites face a challenge due to their inherently insulating nature. While conventional carbon fiber-reinforced composites (CFRP) exhibit electrical conductivity in the...

Fiber-reinforced thermoplastic (FRTP) composites have gained popularity within the aerospace and automotive industries due to their high specific strength-to-weight ratio compared to their metallic counterparts. State-of-the-art composite manufacturing technology such as compression molding (CM) is one of the most used techniques to fabricate FRTPs...

Extrusion-based large-format additive manufacturing (LFAM) often results in unintended deformation and failures due to thermal residual stress between layers. This LFAM involves a hot molten polymer deposited on a previously deposited and cooled layer, generating a temperature mismatch between the layers. The temperature discrepancy causes a therma...

Carbon fiber reinforced polymer (CFRP) composites have gained substantial attention across various industries owing to their exceptional mechanical properties and lightweight nature. The emergence of additive manufacturing technologies brings new opportunities to the industry, offering advantages such as design freedom, rapid prototyping, and custo...

Lightning strike protection (LSP) is one of the prime factors in aerospace and wind industries concerning safety, enhanced service life, and reduced downtime. To ensure better LSP, high electrical conductivity is required to dissipate the current, which is always a challenge for polymer composites due to the inherent insulating nature of the polyme...

Polymeric heat exchangers (PHXs) have been used in applications involving weight restrictions, chemical compatibility, and fouling issues. Additive manufacturing (AM) or 3D printing provide new solutions to previously inaccessible combinations of properties and geometries. There are some advancements in the PHXs by AM; however, the process and the...

With the advent of additive manufacturing, lattice structures have been of increasing interest for engineering applications involving light‐weighting and energy absorption. Several studies have investigated mechanical properties of various lattices made up of mostly unreinforced polymers and lack numerical analysis for reinforced lattice structures...

Carbon fiber (CF) reinforced composites are high-performing, highly utilized material systems historically used in aerospace. As the cost of CF decreases, other industries, such as automotive and energy generation, seek to adopt CF composites into their applications. A sudden increase in CF demand may create supply chain issues if the adoption happ...

Autoclave processing is a commonly used state-of-the-art fiber-reinforced composite manufacturing technology, albeit with high capital cost, long cycle times and high energy consumption. Alternatively, out-of-autoclave processing reduces the initial and operating costs while producing composite structures with similar quality as that of autoclave p...

Metal polymer composites combining low density, high strength composites with highly ductile and tough metals have gained traction over the last few decades as lightweight and high-performance materials for industrial applications. However, the mechanical properties are limited by the interfacial bonding strength between metals and polymers achieve...

Thermoset composites are strong candidates for large-scale material extrusion additive manufacturing (AM). However, uncured thermoset composites become unstable as print height increases. Here, chemical initiation of vinyl ester immediately before deposition was used to suppress collapse and enable large-scale thermoset printing. Structural stabili...

Material extrusion additive manufacturing is prone to introducing porosity within the structure due to the layer-by-layer construction using elliptical beads of material. This open porosity ultimately plays a role in determining the mechanical properties of printed parts. The shape, size, and amount of porosity within a printed part is influenced b...

Large format additive manufacturing (AM) is being adapted as a method of producing large structures in a short lead time and cost-effective way. With the growing advancement in AM techniques and application, machine monitoring and part qualification is highly needed. There has been leading research focused on the manufacturing development and feeds...

Large format additive manufacturing (AM) enables rapid manufacturing of large parts and structures with minimum waste in material and energy. Extrusion‐based AM deposition processes provide parts with highly anisotropic thermal properties, which are not typically reflected in textbook values for these materials. In order to develop accurate models...

In this study, anisotropic stiffness tensors were reconstructed based on fiber orientation distributions obtained from X-ray computer tomography (xCT). A preform was manufactured via a big area additive manufacturing (BAAM) system with carbon fiber (CF) filled acrylonitrile butadiene styrene (ABS). The tailored preform from additive manufacturing (...

Large scale additive manufacturing (AM) of fiber-reinforced polymer composites has gained traction in the mold and die community over the last decade, largely due to reduced material cost and lead time. However, limitations in mold size remain present due to printer volume constraints and costs associated with large format machines. This paper desc...

Recent developments have enabled material extrusion additive manufacturing of thermoset-based composite inks on the large scale. In addition, printing out-of-plane components is of broad interest to the polymer material extrusion community. This work addresses some of the challenges associated with both large-scale and out-of-plane thermoset materi...

A dual-hopper feed system that was developed for the Big Area Additive Manufacturing (BAAM) system allows for transitioning between different materials while maintaining continuous deposition. This technique creates a step-change in material feedstock by switching the pellet feeding system to alternate which hopper is currently supplying material,...

Additive Manufacturing (AM) or 3-D printing has advanced from small-scale desktop printers to large-scale printers. Most of the present large-scale printers utilize feedstock materials in the form of pellets to create composite structures. To create structurally robust composite parts, reinforcements in the form of short fibers (carbon or glass) ar...

Recent advances in additive manufacturing of continuous fibers, combined with traditional infiltration processes, have enabled the fabrication of ceramic matrix composite (CMC) components with complex shapes, which until recently had not been possible with conventional manufacturing processes. In this work, we report results of the manufacturing pr...

Carbon fiber reinforced polymer composites (CFPC) have been used in additive manufacturing (AM) due to both the high-strength-to-weight and superior-stiffness-to-weight ratios. CF AM is being considered for tooling applications. In AM, CFPCs are usually aligned along the deposition direction; however, it results in anisotropic thermal properties wh...

Large-scale material extrusion additive manufacturing technology is becoming the new mainstream technology for scaled-up composite mold and die applications. This paradigm shift in composite processing technology is primarily driven by out-of-autoclave tooling applications, in which fiber reinforced composite molds with scaled-up sizes and embedded...

MXene-based Lightning Strike Protection Coating In article number 2100803, Vipin Kumar and co-workers investigate MXene as an effective filler to improve the electrical and mechanical properties of divinylbenzene (DVB) thermosetting resin. Its performance as a lightning strike protection coating for carbon fiber reinforced polymer (CFRP) is evaluat...

Plate-based lattices are predicted to reach theoretical Hashin–Shtrikman and Suquet upper bounds on stiffness and strength. However, simultaneously attaining high energy absorption in these plate-lattices still remains elusive, which is critical for many structural applications such as shock wave absorber and protective devices. In this work, we pr...

Ti3C2 – a member of the MXenes (two-dimensional (2D) transition metal carbides and nitrides) family, is investigated as an effective filler to improve the electrical, mechanical, and thermal properties of divinylbenzene (DVB) thermosetting resin. Consequently, its performance as a lightning strike protection (LSP) coating for carbon fiber reinforce...

As additive manufacturing (AM) continues to develop and become a standardized manufacturing method, there will be a continued need to provide in-situ monitoring during the manufacturing of polymer composite printed components. Thermal residual stress is a primary cause of failures such as interlayer disbonds or delamination, micro cracking, and dim...

3D printing by fused deposition modeling (FDM) is an advanced additive manufacturing technology for making thermoplastic-based structures. Several studies have recently investigated 3D printing of poly-lactic acid (PLA) with biomass resources like cellulose, hemicellulose, lignin and whole biomass. Such biodegradable composites are better for the e...

Cellulose nanofiber templating has emerged as a unique and facile strategy to prepare advanced materials. In article number 2005538, Meghan E. Lamm, Soydan Ozcan, and co‐workers examine how researchers are exploiting this process to produce high‐performance materials for a range of applications. This promising work thrusts cellulose nanofibers into...

Microfibrillated cellulose (MFC) is widely used as a reinforcement filler for biocomposites due to its unique properties. However, the challenge of drying MFC and the incompatibility between nanocellulose and polymer matrix still limits the mechanical performance of MFC-reinforced biocomposites. In this study, we used a water-based transesterificat...

Hybrid tooling is an emerging concept introduced in the aerospace industries to reduce weight and cost of traditional tools. A hybrid tool features a skin, which provides desired surface quality, durability, and a low‐density substrate to reduce the weight of the mold. The big area additive manufacturing (BAAM) technology permits rapid production o...

Long fiber thermoplastic (LFT) composites are processed either with extrusion compression or fiber injection processes. The properties of LFT materials are highly influenced by processing techniques, which lead to different porosity contents, fiber length distributions, and fiber orientation distributions. It is important to understand the various...

The current severe acute respiratory syndrome coronavirus 2 (SARS-COV-2) pandemic has highlighted the need for personal protective equipment, specifically filtering facepiece respirators like N95 masks. While it is common knowledge that polypropylene (PP) is the industry standard material for filtration media, trial and error is often required to i...

Integrating Multiple Materials (MM) into large-scale Additive Manufacturing (AM) is a key for various industrial applications wishing to incorporate site-specific properties into geometrically complex designs that are difficult to manufacture with traditional techniques. Printing with multiple materials is typically accomplished by using layers as...

In this work, large-scale multimaterial preforms produced by additive manufacturing (AM) underwent compression molding (CM) to produce high-performance thermoplastic composites reinforced with short carbon fibers. AM and CM techniques were integrated to control the fiber orientation (microstructure) and to reduce void content for the improved mecha...

Additive Manufacturing (AM) of carbon fiber (CF) reinforced composite has received growing attention because of the design flexibility, superior mechanical properties, improved thermal properties, and weight reduction. Autoclave tooling was proven to be a successful application for large scale AM technology. The capital cost, and cost associated wi...

Discontinuous short carbon fiber reinforced thermoplastic composites (DS-CFRTP) are being used extensively in interior parts of aircraft such as electronic circuitry and assemblies. In recent years researchers have been trying to increase the use of the thermoplastic composite in primary structures as well. A lightning strike study on DS-CFRTP is p...

Richard Feynman’s famous words, “there’s plenty of room at the bottom,” referred to the opportunities for revolutionizing the electronics industry by developing the science and technology of how to manufacture very small components (sub-micron to nanometer sized features) [1]. In additive manufacturing (AM), the opposite may be true: There’s plenty...

Fabrication of renewable materials through additive manufacturing using wood-filled polylactic acid (PLA) is an emerging field of study. The variability in the tensile properties of 3D-printed materials due to the variability in woody biomass properties has not been studied. Biomass size reduction, filament extrusion, and 3D-printing methods were i...

Thermoset polymer composites show promise for additive manufacturing (AM) applications to address some of the limitations of the more widely used thermoplastic feedstock materials. Thermosets offer attractive mechanical properties while providing excellent interlayer bonding, high thermal and chemical stability, and reduced energy consumption as a...

Additive Manufacturing (AM) or 3-D printing has moved from small-scale prototypes to large-scale functional structures. With the introduction of large-scale 3D printers into the market a new industry has been born. For the first time, we are presenting the idea of preparing large-scale 3-D printed β-stage preforms to be used in traditional compress...

Carbon Fiber Reinforced Polymer (CFRP) composites have been used in additive manufacturing (AM) to increase the stiffness and strength of the parts. CFRP produced by AM is being considered for tooling applications. In AM, short carbon fibers are aligned along the deposition direction. However, it results in anisotropic thermal properties that affec...

Wood and lignocellulosic-based material components are explored in this review as functional additives and reinforcements in composites for extrusion-based additive manufacturing (AM) or 3D printing. The motivation for using these sustainable alternatives in 3D printing includes enhancing material properties of the resulting printed parts, while pr...

Until recently, glass fiber composites (GFRP) were the preferred choice to prepare wind turbine blades due to their low cost compared to their counterpart carbon fiber composites (CFRP). However, to harvest the maximum wind energy, ever larger wind turbine blades are being manufactured. To support such a large structure carbon fiber composites CFRP...

Extrusion based big area additive manufacturing process is utilized for fabrication of dense anisotropic bonded magnets. High loading fraction (≥70 vol%) of magnequench anisotropic Nd–Fe–B powder in nylon is used for preparing anisotropic bonded magnets. A higher energy product of ~143.2 kJ/m³ is obtained for the post printed magnetic field aligned...

Large-scale extrusion-based additive manufacturing of high-performance thermoplastic composites like fiber reinforced polyphenylene sulfide (PPS) is well-suited for tooling applications to lower manufacturing costs and lead times. Autoclave tooling requires good mechanical performance at temperatures even above the glass transition temperature (Tg)...

The use of Multiple Materials (MM) in Additive Manufacturing (AM) is increasingly important for expanding the range of applications in the manufacturing industry, particularly for large-format processes. Typically, polymer-based AM incorporates MM transitions through discrete interfaces between layers. This arrangement significantly increases the o...

Big Area Additive Manufacturing (BAAM) technology allows for manufacturing of large-scale objects with a potential to reduce energy embedded in products, reduce or eliminate energy necessary for transportation of goods along with reducing the lead time and cost in some cases. Over the last few years, Oak Ridge National Laboratory (ORNL) has been fo...

Additively manufactured parts made with polymer extrusion techniques can be 50–75 % weaker in the z-direction (across layers) than in the x- and y-directions. This has been attributed to poor mobility of polymer chains and a low degree of entanglement across a cold deposition interface. This is particularly a challenge when printing large-scale par...

Additive manufacturing (AM) is evolving from rapid prototyping to production of structural components. The widespread application of AM demands a high level of mechanical performance from these components, and it is therefore essential to improve feedstock material in order to meet these mechanical expectations. However, compared to traditional man...

To develop new materials for extrusion additive manufacturing (AM) systems, a fundamental understanding of rheological properties is essential to correlate the effect of processing on material structure and its properties. In this work, the rheological properties of five different grades of neat and carbon fiber (CF)‐reinforced poly(ether ketone ke...

Direct Energy Deposition (DED) systems are currently used to repair and maintain existing parts in the aerospace and automotive industries. This paper discusses an effort to scale up the DED technique in order to Additively Manufacture (AM) molds and dies used in the composite manufacturing industry. The US molds and dies market has been in a rapid...

Carbon fiber reinforced polymer (CFRP) composite is known for its high stiffness-to-weight ratio and hence is of great interest in several engineering fields such as aerospace, automotive, defense, etc. However, such a composite is not suitable for energy dissipation as failure occurs with very little or no plastic deformation. Herein, we present a...

In recent years, Carbon Fiber Reinforced Plastics (CFRP) or Glass Fiber Reinforced Plastics (GFRPs) have become a very common material for aircraft and wind turbine structures. These structures are often protected from lightning strikes using conventional metal-based protective films/foils. Non-conventional, non-metallic lightning strike protection...

Anisotropy of mechanical properties is characteristic of components printed using processes like extrusion deposition additive manufacturing, wherein the properties along the print direction (x-direction) are superior when compared to the corresponding properties in the build direction (z-direction). This effect, influenced by the bond strength in...

Additive manufacturing's (AM) layer-by-layer nature is well-suited to the production of Functionally Graded Materials (FGM) with discrete material boundaries. Extrusion deposition is especially advantageous since multiple nozzles easily accommodate the inclusion of additional materials. However, discrete interfaces and sudden composition changes ca...

Extrusion deposition additive manufacturing produces parts with inherent porosity, which typically manifests as easily accessible voids between beads. This open porosity can also be accompanied by voids within the beads themselves, and both types can impact a part’s desired performance. Porosity is influenced by a variety of factors, including infi...

Invited Talk

Electrically conductive adhesive layers were deposited on top of aerospace grade carbon fiber reinforced plastic (CFRP) panels using a small-scale 3D printer. Polylactic acid (PLA) filaments with copper filler (CU-PLA) and graphene filler (GO-PLA) were used to print around 0.7 mm thick electrically conductive layer on top of CFRP panels. 3D printed...

Manufacturing of Carbon Fiber Reinforced Plastics (CFRPs) using additive manufacturing (AM), or 3D printing, has gained popularity in recent years. It is believed that the AM industry has the potential to manufacture CFRP parts in a faster, easier and more economical way. Lightning strike damage to CFRP parts is not rare; therefore, additional ligh...

Carbon fiber (CF)-reinforced thermoplastic composites have been widely used in different structural applications due to their superior thermal and mechanical properties. The big area additive manufacturing (BAAM) system, developed at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility, has been used to manufacture several composite...

In this work, we describe an efficient and environmentally benign method of recycling of additive printed Nd-Fe-B polymer bonded magnets. Rapid pulverization of bonded magnets into composite powder containing Nd-Fe-B particles and polymer binder was achieved by milling at cryogenic temperatures. The recycled bonded magnets fabricated by warm compac...

For the successful transition of additive manufacturing (AM) from prototyping to manufacturing of structural load bearing parts, feedstock systems with improved mechanical properties are needed. In terms of sustainability and environmental impact, selection of biobased renewable alternatives instead of petroleum-based options is important. Nanocell...

Additively manufactured parts have an inherent mesostructure as a result of printing artifacts. The build structure is defined by parameters such as infill pattern, raster spacing, and bead height, and can impart anisotropic thermo-mechanical properties that are different from the bulk properties of the feedstock. The anisotropy is more pronounced...

Conventional 3D printing approaches are restricted to building up material in a layer-by-layer format, which is more appropriately considered “2.5-D” printing. The layered structure inherently results in significant mechanical anisotropy in printed parts, causing the tensile strength in the build direction (z-axis) to be only a fraction of the in-p...