Optimization of Design Process of Fused Filament Fabrication (FFF) 3D Printing

2018 ◽  
Author(s):  
Jaeyoon Kim ◽  
Bruce S. Kang
Keyword(s):  
Mechanical Properties ◽  
Carbon Fiber ◽  
3D Printing ◽  
Design Process ◽  
Design Methodology ◽  
Tool Path ◽  
Fiber Reinforced ◽  
Fused Filament Fabrication ◽  
Principal Directions

Fused Filament Fabrication (FFF) is one of the most common Additive Manufacturing (AM) technologies for thermoplastic materials. PLA, ABS, and nylon have generally been used for prototype development. With the development of carbon fiber reinforced polymer (CFRP) filament for FFF, AM parts with improved strength and functionality can be realized. While mechanical properties of various CFRP have been well studied, design methodology for structural optimization of CFRP parts remains an active research area. In this paper, a systematic optimization of design process of FFF 3D printing methodology is proposed for CFRP. Starting with standard coupon specimen tests including tensile, bending, and creep tests to obtain mechanical properties of CFRP. Finite element analyses (FEA) are conducted to find principal directions of the AM part and computed principal directions are utilized as fiber orientations. Then, the connecting lines of principal directions are used to develop a customized tool-path in FFF 3D printing to extrude fibers aligned with principal directions. Since currently available infill-patterns in 3D printing cannot precisely draw customized lines, a specific tool-path algorithm has been developed to distribute fibers with the desired orientations. To predict/assess mechanical behavior of the AM part, 3D printing process was simulated followed by FEA to obtain the anisotropic structural behavior induced by the customized tool-path. To demonstrate the design/manufacturing methodology, spur gears of a ball milling machine were selected as a case study and carbon fiber reinforced nylon filament was chosen as the AM materials. Relevant compression tests were conducted to assess their performance compared with those printed at regular tool-path patterns. Preliminary results show that CFRP gear printed by customized tool-path has about 8% higher stiffness than those printed by regular patterns. Also, flow distribution of printed fibers was verified using scanning electron microscope (SEM). SEM images showed that approximately 91% of fibers were oriented as intended. In summary, assisted by FEA, a customized 3D printing tool-path for CFRP has been developed with a case study to verify the proposed AM design methodology.

Influence of Layer Thickness and Continuous Carbon Fiber on the Mechanical Property of 3D Printed Polyamide

2020 ◽  
Vol 861 ◽  
pp. 165-169
Author(s):  
Tian Lan ◽  
Li Chao Dong ◽  
Zhong Yuan Lu ◽  
Shi Feng Guo ◽  
Hao Zhang ◽  
...  
Keyword(s):  
Carbon Fiber ◽  
3D Printing ◽  
Layer Thickness ◽  
Fiber Reinforced ◽  
Fused Filament Fabrication ◽  
Carbon Fiber Reinforced Composites ◽  
Continuous Carbon Fiber ◽  
3D Printed ◽  
Carbon Fiber Reinforced ◽  
Interface Bonding Strength

3D printed carbon fiber reinforced composites (CFRP) have shown great potential in lightweight application. Here, we report a prepreg carbon fiber reinforced polyamide composite by fused filament fabrication 3D printing process. The influence of layer thickness and carbon fiber layers on mechanical properties of 3D printed parts was well studied. With the incorporation of prepreg carbon fibers, the value of tension and flexural strengths of 3D printed CFRP parts could achieve 2.7 and 13.6 times compared to neat polyamide, respectively. Result illustrates that with the prepreg process the carbon fiber have good interface bonding strength with neat polyimide. This work could also be used for more 3D printing composite systems.

scholarly journals Effect of Process Parameters on Tensile Mechanical Properties of 3D Printing Continuous Carbon Fiber-Reinforced PLA Composites

Materials ◽  
2020 ◽  
Vol 13 (17) ◽  
pp. 3850 ◽  
Author(s):  
Hao Dou ◽  
Yunyong Cheng ◽  
Wenguang Ye ◽  
Dinghua Zhang ◽  
Junjie Li ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Carbon Fiber ◽  
3D Printing ◽  
Matrix Interface ◽  
Fiber Reinforced ◽  
Layer Height ◽  
Continuous Carbon Fiber ◽  
Fiber Matrix Interface ◽  
Fiber Matrix ◽  
Carbon Fiber Reinforced

Three-dimensional (3D) printing continuous carbon fiber-reinforced polylactic acid (PLA) composites offer excellent tensile mechanical properties. The present study aimed to research the effect of process parameters on the tensile mechanical properties of 3D printing composite specimens through a series of mechanical experiments. The main printing parameters, including layer height, extrusion width, printing temperature, and printing speed are changed to manufacture specimens based on the modified fused filament fabrication 3D printer, and the tensile mechanical properties of 3D printing continuous carbon fiber-reinforced PLA composites are presented. By comparing the outcomes of experiments, the results show that relative fiber content has a significant impact on mechanical properties and the ratio of carbon fibers in composites is influenced by layer height and extrusion width. The tensile mechanical properties of continuous carbon fiber-reinforced composites gradually decrease with an increase of layer height and extrusion width. In addition, printing temperature and speed also affect the fiber matrix interface, i.e., tensile mechanical properties increase as the printing temperature rises, while the tensile mechanical properties decrease when the printing speed increases. Furthermore, the strengthening mechanism on the tensile mechanical properties is that external loads subjected to the components can be transferred to the carbon fibers through the fiber-matrix interface. Additionally, SEM images suggest that the main weakness of continuous carbon fiber-reinforced 3D printing composites exists in the fiber-matrix interface, and the main failure is the pull-out of the fiber caused by the interface destruction.

scholarly journals 3D-Printed Carbon Fiber Reinforced Polymer Composites: A Systematic Review

2020 ◽  
Vol 4 (3) ◽  
pp. 98 ◽  
Author(s):  
Seyed Hamid Reza Sanei ◽  
Diana Popescu
Keyword(s):  
Mechanical Properties ◽  
Carbon Fiber ◽  
3D Printing ◽  
Fiber Orientation ◽  
Fiber Reinforced Composites ◽  
Carbon Fiber Composites ◽  
Reinforced Composites ◽  
Fiber Reinforced ◽  
3D Printed ◽  
Carbon Fiber Reinforced

Fiber reinforced composites offer exceptional directional mechanical properties, and combining their advantages with the capability of 3D printing has resulted in many innovative research fronts. This review aims to summarize the methods and findings of research conducted on 3D-printed carbon fiber reinforced composites. The review is focused on commercially available printers and filaments, as their results are reproducible and the findings can be applied to functional parts. As the process parameters can be readily changed in preparation of a 3D-printed part, it has been the focus of many studies. In addition to typical composite driving factors such as fiber orientation, fiber volume fraction and stacking sequence, printing parameters such as infill density, infill pattern, nozzle speed, layer thickness, built orientation, nozzle and bed temperatures have shown to influence mechanical properties. Due to the unique advantages of 3D printing, in addition to conventional unidirectional fiber orientation, concentric fiber rings have been used to optimize the mechanical performance of a part. This review surveys the literature in 3D printing of chopped and continuous carbon fiber composites to provide a reference for the state-of-the-art efforts, existing limitations and new research frontiers.

scholarly journals Enhancing Structural Performance of Short Fiber Reinforced Objects through Customized Tool-Path

2020 ◽  
Vol 10 (22) ◽  
pp. 8168
Author(s):  
Jaeyoon Kim ◽  
Bruce S. Kang
Keyword(s):  
Mechanical Properties ◽  
3D Printing ◽  
Mechanical Behavior ◽  
Case Studies ◽  
Fused Deposition Modeling ◽  
Tool Path ◽  
Spur Gear ◽  
Fiber Reinforced ◽  
Printing Process ◽  
Fused Deposition

Fused deposition modeling (FDM) is one of the most common additive manufacturing (AM) technologies for thermoplastic materials. With the development of carbon fiber-reinforced polymer (CFRP) filament for FDM, AM parts with improved strength and functionality can be realized. CFRP is anisotropic material and its mechanical properties have been well studied, however, AM printing strategy for CFRP parts has not been developed. This paper proposes a systematic optimization of the FDM 3D printing process for CFRP. Starting with standard coupon specimen tests to obtain mechanical properties of CFRP, finite element analyses (FEA) were conducted to find principal directions of the AM part and utilized to determine fiber orientations. A specific tool-path algorithm has been developed to distribute fibers with the desired orientations. To predict/assess the mechanical behavior of the AM part, the 3D printing process was simulated to obtain the anisotropic mechanical behavior induced by the customized tool-path printing. Bolt hole plate and spur gear were selected as case studies. FE simulations and associated experiments were conducted to assess their performance. CFRP parts printed by the optimized tool-path shows about 8% higher stiffness than those printed at regular infill patterns. In summary, assisted by FEA, a customized 3D printing tool-path for CFRP has been developed with case studies to verify the proposed AM design optimization methodology for FDM.

scholarly journals Generation of Wholly Thermoplastic Composites and Their Processing in Additive Manufacturing

2021 ◽  
Author(s):  
Tianran Chen
Keyword(s):  
Mechanical Properties ◽  
3D Printing ◽  
High Performance ◽  
Liquid Crystalline ◽  
Mechanical Performance ◽  
Crystalline Polymer ◽  
Extrusion Process ◽  
Thermoplastic Composites ◽  
Fiber Reinforced ◽  
Fused Filament Fabrication

3D printing has attracted great interest over the past three decades due to its high precision, less waste generation and design freedom [1-3]. One of the major challenges 3D printing is the poor mechanical performance of pure polymer parts. Researchers used traditional carbon and glass fiber reinforced composites to overcome this issue [4-7]. The traditional fibers can improve the mechanical properties of printed parts. However, the manufacturing techniques and printing process restrict the overall performance of the printed parts. Thermotropic liquid crystalline polymer (TLCP) is another reinforcement which offers lighter weight, lower viscosity, excellent mechanical performance and great recyclability [8-15]. TLCPs are capable of forming extended conformations when subjected to extensional or shear deformation.[16, 17] The formation of highly orientated molecular structure enables the generation of high mechanical properties. In this study, polyamide was reinforced with TLCP by the dual-extrusion technique to generate high performance composite filaments [18]. Rheological tests were used to optimize the processing conditions of the dual-extrusion process, which could minimize the degradation of matrix polymer. High performance and lightweight fiber-reinforced composite parts were fabricated by utilizing the fused filament fabrication (FFF) technique. The composite filaments were printed at the temperature below the melting point of TLCP to avoid the relaxation of TLCP. The mechanical performances of printed parts are greater than 3D printed parts which are reinforced by conventional fibers.

scholarly journals Generation of Wholly Thermoplastic Composites and Their Processing in Additive Manufacturing

2021 ◽  
Author(s):  
Tianran Chen ◽  
Donald Baid
Keyword(s):  
Mechanical Properties ◽  
3D Printing ◽  
High Performance ◽  
Liquid Crystalline ◽  
Mechanical Performance ◽  
Crystalline Polymer ◽  
Extrusion Process ◽  
Thermoplastic Composites ◽  
Fiber Reinforced ◽  
Fused Filament Fabrication

3D printing has attracted great interest over the past three decades due to its high precision, less waste generation and design freedom[1-3]. One of the major challenges 3D printing is the poor mechanical performance of pure polymer parts. Researchers used traditional carbon and glass fiber reinforced composites to overcome this issue [4-7]. The traditional fibers can improve the mechanical properties of printed parts. However, the manufacturing techniques and printing process restrict the overall performance of the printed parts. Thermotropic liquid crystalline polymer (TLCP) is another reinforcement which offers lighter weight, lower viscosity, excellent mechanical performance and great recyclability [8-15]. TLCPs are capable of forming extended conformations when subjected to extensional or shear deformation.[16, 17] The formation of highly orientated molecular structure enables the generation of high mechanical properties . In this study, polyamide was reinforced with TLCP by the dual-extrusion technique to generate high performance composite filaments [18]. Rheological tests were used to optimize the processing conditions of the dual-extrusion process, which could minimize the degradation of matrix polymer. High performance and lightweight fiber-reinforced composite parts were fabricated by utilizing the fused filament fabrication (FFF) technique. The composite filaments were printed at the temperature below the melting point of TLCP to avoid the relaxation of TLCP. The mechanical performances of printed parts are greater than 3D printed parts which are reinforced by conventional fibers.

Investigation of mechanical and fracture behavior of pure and carbon fiber reinforced ABS samples processed by fused filament fabrication process

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Cem Boğa
Keyword(s):  
Mechanical Properties ◽  
Carbon Fiber ◽  
3D Printing ◽  
Mixed Mode ◽  
Fracture Behavior ◽  
Production Method ◽  
Fused Filament Fabrication ◽  
Content Type ◽  
Printing Technique ◽  
3D Printing Technique

Purpose Acrylonitrile butadiene styrene (ABS), as a light and high strength thermoplastic polymer, has found extensive applications in different industries. Fused filament fabrication, known as three-dimensional (3D) printing technique is considered a rapid prototyping technique that is frequently applied for production of samples of ABS material. Therefore, the purpose of this study is to investigate the mechanical and fracture behavior of such materials and the techniques to improve such properties. Design/methodology/approach Experimental and numerical analyses have been conducted to investigate the effects of internal architecture and chopped carbon fiber (CF) fillers on the mechanical properties and mixed mode fracture behavior of the ABS samples made by 3D printing technique. Four different filling types at 70% filling ratios have been used to produce tensile and special fracture test samples with pure and CF filled ABS filaments (CF-ABS) using 3D process. A special fixture has been developed to apply mixed mode loading on fracture samples, and finite element analyses have been conducted to determine the geometric function of such samples at different loading angles. Findings It has been determined that the printing pattern has a significant effect on the mechanical properties of the sample. The addition of 15% CF to pure ABS resulted in a significant increase in tensile strength of 46.02% for line filling type and 15.04% for hexagon filling type. It has been determined that as the loading angle increases from 0° to 90°, the KIC value decreases. The addition of 15% CF increased the KIC values for hexagonal and line filling type by 64.14% and 12.5%, respectively. Originality/value The damage that will occur in ABS samples produced in 3D printers depends on the type, amount, filling speed, filling type, filling ratio, filling direction and mechanical properties of the additives. All these features are clearly dependent on the production method. Even if the same additive is used, the production method difference shows different microstructural parameters, especially different mechanical properties.

Linear translaminar fracture characterization of additive manufactured continuous carbon fiber reinforced thermoplastic

2021 ◽  
pp. 089270572110214
Author(s):  
Weiller M Lamin ◽  
Flávio LS Bussamra ◽  
Rafael TL Ferreira ◽  
Rita CM Sales ◽  
José E Baldo
Keyword(s):  
Fracture Toughness ◽  
Carbon Fiber ◽  
Fracture Mechanics ◽  
Image Correlation ◽  
Fiber Reinforced ◽  
Fused Filament Fabrication ◽  
Critical Energy Release Rate ◽  
Linear Elastic ◽  
Continuous Carbon Fiber ◽  
Carbon Fiber Reinforced

This work presents the experimental determination of fracture mechanics parameters of composite specimens manufactured by fused filament fabrication (FFF) with continuous carbon fiber reinforced thermoplastic filaments, based on Linear Elastic Fracture Mechanics (LEFM). The critical mode I translaminar fracture toughness (KIc) and the critical energy release rate (GIc) are found for unidirectional and cross-ply laminates. The specimens were submitted to quasi-static tensile testing. Digital Image Correlation (DIC) is used to find the stress field. The stress fields around the crack tip are compared to linear elastic finite element simulations. The results demonstrate the magnitude of fracture toughness is in the same range as for polymers and some metals, depending on lay-up configuration. Besides, fractographic analyses show some typical features as river lines, fiber impression, fiber pulls-out and porosity aspects.

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