Date of Defense
21-11-2025 11:00 AM
Location
F1-1043
Document Type
Thesis Defense
Degree Name
Master of Science in Mechanical Engineering (MSME)
College
COE
Department
Mechanical and Aerospace Engineering
First Advisor
Prof. Abdel-Hamid. I. Mourad
Abstract
This work offers a thorough investigation into the performance of 3D-printed, short carbon fiber-reinforced polypropylene pressure vessels, specifically designed for gas storage in demanding sectors like aerospace, drones, and medical equipment, operating within a pressure range of 0-10 bar. A key challenge in FDM additive manufacturing of pressure vessels is achieving airtightness due to the inherent porosity and micro-gaps resulting from the printing process. To address this, the fabricated vessel models were coated with various commercially available materials to effectively fill these microscopic imperfections and ensure the necessary tightness. Spray coating and adhesion coating materials were applied to the outer surface of the vessel models. Although spray coating was simple to apply, it did not fully achieve airtightness. Conversely, while applying Bond + Seal adhesion sealant was challenging due to the high viscosity of the rubbery material, it exhibited superior properties, with no leaks detected, resulting in complete airtightness.
The study systematically evaluated a structural design of three distinct vessel models, varying in uniform wall thickness (1 mm, 2 mm, and 3 mm). Performance was assessed through rigorous pressure testing, utilizing an air compressor and a meticulously designed piping setup to determine the vessels' structural integrity and outstanding capabilities against internal pressure. Interestingly, a 3D printed pressure vessel of 3 mm wall thickness withstands 10 bars operating pressure without bursting, while the 2 mm burst at 8.1 bars. This work highlights the profound significance of such an approach for the future of polymeric pressure vessel manufacturing. The proposed methodology leverages the advantages of 3D printing, offering an easy, sustainable, and cost-effective fabrication process that yields lightweight components with excellent strength, thereby bridging a crucial gap in current manufacturing paradigms for advanced containment solutions.
Included in
INVESTIGATE THE PERFORMANCE AND AIRTIGHTNESS OF SHORT CARBON FIBER REINFORCED POLYPROPYLENE PRESSURE VESSEL FABRICATED VIA FDM 3D PRINTING
F1-1043
This work offers a thorough investigation into the performance of 3D-printed, short carbon fiber-reinforced polypropylene pressure vessels, specifically designed for gas storage in demanding sectors like aerospace, drones, and medical equipment, operating within a pressure range of 0-10 bar. A key challenge in FDM additive manufacturing of pressure vessels is achieving airtightness due to the inherent porosity and micro-gaps resulting from the printing process. To address this, the fabricated vessel models were coated with various commercially available materials to effectively fill these microscopic imperfections and ensure the necessary tightness. Spray coating and adhesion coating materials were applied to the outer surface of the vessel models. Although spray coating was simple to apply, it did not fully achieve airtightness. Conversely, while applying Bond + Seal adhesion sealant was challenging due to the high viscosity of the rubbery material, it exhibited superior properties, with no leaks detected, resulting in complete airtightness.
The study systematically evaluated a structural design of three distinct vessel models, varying in uniform wall thickness (1 mm, 2 mm, and 3 mm). Performance was assessed through rigorous pressure testing, utilizing an air compressor and a meticulously designed piping setup to determine the vessels' structural integrity and outstanding capabilities against internal pressure. Interestingly, a 3D printed pressure vessel of 3 mm wall thickness withstands 10 bars operating pressure without bursting, while the 2 mm burst at 8.1 bars. This work highlights the profound significance of such an approach for the future of polymeric pressure vessel manufacturing. The proposed methodology leverages the advantages of 3D printing, offering an easy, sustainable, and cost-effective fabrication process that yields lightweight components with excellent strength, thereby bridging a crucial gap in current manufacturing paradigms for advanced containment solutions.