Upgraded our smart helmets to cater to #military needs.

The attached images showcase how we replaced the top slat of our helmet with one that was printed using Markforged continuous fiber reinforcement (CFR) with #kevlar.

Thank you Grant Michel from Würth Additive Group for helping us on this adventure and figuring out the orientation and the right amount of fill.

Notes from Markforged’s Eiger process: https://markforged.com/resources/learn/design-for-additive-manufacturing-plastics-composites/3d-printing-composites-introduction/3d-printing-composites-with-markforged

CFR is a process that enables 3D printers to reinforce parts with continuous fibers. A CFR-capable machine uses two extrusion systems: one for conventional filament, and a second for long strand continuous fibers. Continuous Fibers are laid down in-layer, replacing regular filament infill.

Continuous fibers, including fiberglass, carbon fiber, and Kevlar, are what endow a composite part with the directional strength of metal. They have elastic moduli between 16 times and 46 times greater than those of plastics, with carbon fiber’s being almost equivalent to aluminum’s (60 GPa and 69 GPa, respectively). As opposed to chopped fibers being suspended in the plastic, continuous fibers run uninterrupted through a part, thus distributing the load across the three-dimensional geometry.

Because of their distinct properties, fibers require a different 3D printing method from FDM. They are not melted and extruded like plastic, but instead are laid down intact through a secondary print nozzle. As this happens, a thin plastic coating around the fiber melts so that they adhere to the matrix. This type of composite-building is called Continuous Fiber Fabrication (CFF), and it is unique to Markforged printers.

How does the printer know where to put fiber? All compositing parameters are defined in Markforged’s slicing software, Eiger. After the user has indicated which layers get fiber, how much, and in what pattern, the software instructs the printer to place solid-infill “floor” layers above and below the region which includes fiber, as well as when to switch between plastic infill and continuous fiber routing.

Such enhancements are part of a series of undertakings to modernize the industrial base to enable both the military/government and the commercial sector to avail of the advances in manufacturing and digital technologies. There are several use cases for the military that we are working on.

Numorpho Cybernetic Systems (NUMO) is committed to utilize such advances in Additive Manufacturing and enable smart and connected solutions utilizing our partner network of platform and tools providers, manufacturers and solution providers to create an ecosystem to cater to the demanding needs of the customer and the future.

Alexander S. Joe Tonoff

NITIN UCHIL – Founder, CEO & Technical Evangelist
nitin.uchil@numorpho.com