Programmable laser curing of carbon fiber laminate structures

Abstract

Abstract Carbon fiber composites have revolutionized various industries due to their exceptional mechanical properties and lightweight nature. However, the conventional curing processes used in their manufacturing are often time-consuming and energy-intensive. In this study, we propose an alternative approach utilizing blue and red lasers for the selective curing of carbon fiber-reinforced polymer (CFRP) laminates, enabling the development of deployable structures. Laser curing offers several advantages over traditional methods, including precise control over curing parameters, rapid heating and cooling rates, and localized energy delivery. This fabrication method is ideal for applications in deployable design. Deployable structures have become increasingly popular due to their ease of assembly and compact storage capabilities. They are often made from lightweight and durable materials and are designed to be assembled quickly with minimal tools and expertise required. Origami principles have been used to design deployable structures that can be collapsed and deployed along the same path, and pop-up design techniques have also been used to create articulated three-dimensional structures that can be fabricated starting from a flattened state. In this context, two laser fabrication methods are presented and a deployable, pop-up carbon fiber reinforced polymer (CFRP) lattice structure is developed, as well as a ruled surface structure. For the first strategy,a blue laser is used to selectively cure parts of the flattened CFRP design, creating hinges that allow the entire structure to be deployed in a pop-up manner. In the second strategy, a red laser is used to ablate epoxy from the prepreg carbon fiber, leaving areas that are more flexible than the surrounding areas once the entire structure is cured. This design and fabrication method yields a deployable structure with many potential applications in aerospace fields.