There is a potential for direct model manufacturing of abdominal aortic aneurysm (AAA) using 3D printing technique for generating flexible semi-transparent prototypes. A patient-specific AAA model was manufactured using fused deposition modelling (FDM) 3D printing technology. A flexible, semi-transparent thermoplastic polyurethane (TPU), called Cheetah Water (produced by Ninjatek, USA), was used as the flexible, transparent material for model manufacture with a hydrophilic support structure 3D printed with polyvinyl alcohol (PVA). Printing parameters were investigated to evaluate their effect on 3D–printing precision and transparency of the final model. ISO standard tear resistance tests were carried out on Ninjatek Cheetah specimens for a comparison of tear strength with silicone rubbers. It was found that an increase in printing speed decreased printing accuracy, whilst using an infill percentage of 100% and printing nozzle temperature of 255 °C produced the most transparent results. The model had fair transparency, allowing external inspection of model inserts such as stent grafts, and good flexibility with an overall discrepancy between CAD and physical model average wall thicknesses of 0.05 mm (2.5% thicker than the CAD model). The tear resistance test found Ninjatek Cheetah TPU to have an average tear resistance of 83 kN/m, higher than any of the silicone rubbers used in previous AAA model manufacture. The model had lower cost (4.50 GBP per model), shorter manufacturing time (25 h 3 min) and an acceptable level of accuracy (2.61% error) compared to other methods. It was concluded that the model would be of use in endovascular aneurysm repair planning and education, particularly for practicing placement of hooked or barbed stents, due to the model’s balance of flexibility, transparency, robustness and cost-effectiveness.

The through‐thickness conductivity of carbon fiber reinforced polymer (CFRP) composite was increased by incorporating multiwalled carbon nanotubes in the interlaminar region. Carbon nanotubes (CNTs) were dispersed in a polyethylenimine (PEI) binder, which was then coated onto the carbon fiber fabric. Standard vacuum‐assisted resin infusion process was applied to fabricate the composite laminates. This modification technique aims to enhance the electrical conductivity in through‐thickness direction for the purpose of nondestructive testing, damage detection, and electromagnetic interference shielding. CNT concentrations ranging from 0 to 0.75 wt% were used and compared to pristine CFRP samples (reference). The through‐thickness conductivity of the CFRP exhibited an improvement of up to 781% by adopting this technique. However, the dispersion of CNT in PEI led to a viscosity increase and poor wetting properties which resulted in the formation of voids/defects, poor adhesion (as shown in scanning electron micrographs) and the deterioration of the mechanical properties as manifested by interlaminar shear strength and dynamic mechanical analysis measurements.

This paper explores the performance of low-cost unidirectional carbon fibre towpregs with respect to line production speed and fibre volume fraction. Using an automated production line, towpregs were produced at different production speeds, resulting in modified fibre volume fractions. The towpregs were used to manufacture unidirectional composite plates, which were then tested to evaluate mechanical performance. The fibre straightness and interfacial void ratio of the composite plates were determined by statistical analysis of the samples’ optical micrographs. The results demonstrate that adjusting the line production speed enables targeted fibre volume fractions (FVF) to be reached, resulting in the composites having different mechanical performances (2039 MPa and 2186.7 MPa tensile strength, 1.26 and 1.21 GPa flexural strength for 59.8% and 64.4% FVF, respectively). It was shown that at lower production speeds and FVF, composites exhibit good consolidation and low porosity, which is highlighted by the better interlaminar shear strength performances (8.95% increase), indicating the limitations of manufacturing very high FVF composites. Furthermore, it was concluded that fibre straightness plays a key role in mechanical performance, as samples with a lesser degree of fibre straightness showed a divergence from theoretical tensile properties.

Powder epoxy composites have several advantages for the processing of large composite structures, including low exotherm, viscosity and material cost, as well as the ability to carry out separate melting and curing operations. This work studies the mode I and mixed-mode toughness, as well as the in-plane mechanical properties of unidirectional stitched glass and carbon fibre reinforced powder epoxy composites. The interlaminar fracture toughness is studied in pure mode I by performing Double Cantilever Beam tests and at 25% mode II, 50% mode II and 75% mode II by performing Mixed Mode Bending testing according to the ASTM D5528-13 test standard. The tensile and compressive properties are comparable to that of standard epoxy composites but both the mode I and mixed-mode toughness are shown to be significantly higher than that of other epoxy composites, even when comparing to toughened epoxies. The mixed-mode critical strain energy release rate as a function of the delamination mode ratio is also provided. This paper highlights the potential for powder epoxy composites in the manufacturing of structures where there is a risk of delamination.

The tensile fracture mechanics and thermo-mechanical properties of mixtures composed of two kinds of epoxy resins of different chemical structures and functional groups were studied. The base resin was a bi-functional epoxy resin based on diglycidyl ether of bisphenol-A (DGEBA) and the other resins were (a) distilled triglycidylether of meta-amino phenol (b) 1, 6–naphthalene di epoxy and (c) fluorene di epoxy. This research shows that a small number of multifunctional epoxy systems, both di- and tri-functional, can significantly increase tensile strength (14%) over neat DGEBA while having no negative impact on other mechanical properties including glass transition temperature and elastic modulus. In fact, when compared to unmodified DGEBA, the tri-functional epoxy shows a slight increase (5%) in glass transition temperature at 10 wt.% concentration. The enhanced crosslinking of DGEBA (90 wt.%)/distilled triglycidylether of meta-amino phenol (10 wt.%) blends may be the possible reason for the improved glass transition. Finally, the influence of strain rate, temperature and moisture were investigated for both the neat DGEBA and the best performing modified system. The neat DGEBA was steadily outperformed by its modified counterpart in every condition.