Reactive Additive Manufacturing Simulation of Thermoset Nano Graphene Inclusion

During the 3D printing of graphene platelet inclusion in resin, residual stresses due to thermal loading can cause wrinkle/distortion of final part. This paper presents a multi-scale modeling approach to reduce the residual thermal stress at the interphase between inclusion and resin. Material characterization is performed utilizing an integrated multi-scale modeling approach: (a) nano modeling examines effect of defects such as void shape/size/distribution, platelet orientation, etc.); (b) micro-mechanics examines constituents (platelet/matrix/interphase, residual stress); (c) macro-mechanics examines the delamination and debonding. De-homogenized multi-scale modeling approach provides detailed stiffness/strength to Finite Element Model (FEM) for full structural/thermal progressive failure analysis to address wrinkling/distortion, damage and delamination evolution via cohesive traction separation.