Effects of Process Variables on Extrusion of Carbon Fiber Reinforced ABS Filament for Additive Manufacturing

2015 ◽  
Author(s):  
Emmett Hull ◽  
Weston Grove ◽  
Meng Zhang ◽  
Xiaoxu Song ◽  
Z. J. Pei ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Carbon Fiber ◽  
Computer Aided Design ◽  
Fused Deposition Modeling ◽  
Layer By Layer ◽  
Fiber Reinforced ◽  
Process Variables ◽  
Fused Deposition ◽  
3D Printers ◽  
Carbon Fiber Reinforced

Additive manufacturing (3D printing) is a class of manufacturing processes where material is deposited in a layer-by-layer fashion to fabricate a three-dimensional part directly from a computer-aided design (CAD) model. With a current market share of 44%, thermoplastic-based additive manufacturing such as fused deposition modeling (FDM) is a prevailing technology. A preliminary extrusion process is required to produce thermoplastic filaments for use in FDM 3D printers. It is crucial that extruded filament must have constant dimensional accuracy for FDM 3D printers to produce the desired object with precision. In this study, carbon fibers were blended with acrylonitrile butadiene styrene (ABS) thermoplastics to produce carbon fiber reinforced ABS filaments in order to improve the mechanical properties of FDM-printed objects. During filament extrusion, three process variables showed significant effects on filament diameter, expansion percentage, and extrusion rate. These process variables included carbon fiber content, extrusion temperature, and nozzle size. The objective of this study is to test the feasible ranges of these process variables and to investigate their effects on filament extrusion. Results of this study will provide knowledge on quality improvement of carbon fiber reinforced ABS filament extrusion for additive manufacturing.

Manufacturing and Characterization of Continuous Carbon Fiber Reinforced Polymer Composites

2020 ◽  
Author(s):  
Hongbin Choi ◽  
Peyman Honarmandi
Keyword(s):  
Carbon Fiber ◽  
Fused Deposition Modeling ◽  
Complex Geometries ◽  
Layer By Layer ◽  
Fibrous Materials ◽  
Fiber Reinforced ◽  
Fused Deposition ◽  
Fiber Reinforced Polymer Composites ◽  
Carbon Fiber Reinforced ◽  
Treated Carbon

Abstract Additive manufacturing (AM), also popularly known as 3D-printing technology, is innovative as it manufactures a part by adding small portions of materials layer by layer, instead of removing materials from a larger bulk. This technology allows designers to create and manufacture many complex geometries. There are several AM techniques but this research focuses on fused deposition modeling (FDM) technique due to its relatively cheaper price tag and robustness. Although FDM is great at manufacturing complex geometries, the produced parts are weaker compared to the ones manufactured by the traditional techniques due to the weak layer adhesion, porous inner structure and poor surface finish. To overcome the limitations of the technology, this research was focused on reinforcing 3D-printed parts with continuous fibrous materials. In composite materials, previous studies show that among the numerous ways to inserting carbon fibers, direct insertion method yields the best results. Since none of the prior studies present standardized manufacturing and post-processing protocol, this research seeks to address this issue by developing and presenting the detailed protocols for both processes and fully characterize the created composite material experimentally. The result shows that heat-treated carbon fiber reinforced sample has exceptional increases in mechanical properties. Most notably, yield strength and resilience compared to the stock sample, increase by whopping 60% and 64% respectively.

Carbon Nanotube Reinforced Fused Deposition Modeling Using Microwave Irradiation

2016 ◽  
Author(s):  
Meng Zhang ◽  
Xiaoxu Song ◽  
Weston Grove ◽  
Emmett Hull ◽  
Z. J. Pei ◽  
...  
Keyword(s):  
Carbon Nanotubes ◽  
Carbon Nanotube ◽  
Additive Manufacturing ◽  
Microwave Irradiation ◽  
Computer Aided Design ◽  
Fused Deposition Modeling ◽  
Layer By Layer ◽  
Sem Images ◽  
Fused Deposition ◽  
Deposition Modeling

Additive manufacturing (AM) is a class of manufacturing processes where material is deposited in a layer-by-layer fashion to fabricate a three-dimensional part directly from a computer-aided design model. With a current market share of 44%, thermoplastic-based additive manufacturing such as fused deposition modeling (FDM) is a prevailing technology. A key challenge for AM parts (especially for parts made by FDM) in engineering applications is the weak inter-layer adhesion. The lack of bonding between filaments usually results in delamination and mechanical failure. To address this challenge, this study embedded carbon nanotubes into acrylonitrile butadiene styrene (ABS) thermoplastics via a filament extrusion process. The vigorous response of carbon nanotubes to microwave irradiation, leading to the release of a large amount of heat, is used to melt the ABS thermoplastic matrix adjacent to carbon nanotubes within a very short time period. This treatment is found to enhance the inter-layer adhesion without bulk heating to deform the 3D printed parts. Tensile and flexural tests were performed to evaluation the effects of microwave irradiation on mechanical properties of the specimens made by FDM. Scanning electron microscopic (SEM) images were taken to characterize the fracture surfaces of tensile test specimens. The actual carbon nanotube contents in the filaments were measured by conducting thermogravimetric analysis (TGA). The effects of microwave irradiation on the electrical resistivity of the filament were also reported.

scholarly journals The Micro–Macro Interlaminar Properties of Continuous Carbon Fiber-Reinforced Polyphenylene Sulfide Laminates Made by Thermocompression to Simulate the Consolidation Process in FDM

Polymers ◽  
2022 ◽  
Vol 14 (2) ◽  
pp. 301
Author(s):  
Jiale Hu ◽  
Suhail Mubarak ◽  
Kunrong Li ◽  
Xu Huang ◽  
Weidong Huang ◽  
...  
Keyword(s):  
Carbon Fiber ◽  
3D Printing ◽  
Manufacturing Industry ◽  
Fused Deposition Modeling ◽  
Polyphenylene Sulfide ◽  
Fiber Reinforced ◽  
Continuous Fiber ◽  
Fused Deposition ◽  
Continuous Carbon Fiber ◽  
Carbon Fiber Reinforced

Three-dimensional (3D) printing of continuous fiber-reinforced composites has been developed in recent decades as an alternative means to handle complex structures with excellent design flexibility and without mold forming. Although 3D printing has been increasingly used in the manufacturing industry, there is still room for the development of theories about how the process parameters affect microstructural properties to meet the mechanical requirements of the printed parts. In this paper, we investigated continuous carbon fiber-reinforced polyphenylene sulfide (CCF/PPS) as feedstock for fused deposition modeling (FDM) simulated by thermocompression. This study revealed that the samples manufactured using a layer-by-layer process have a high tensile strength up to 2041.29 MPa, which is improved by 68.8% compared with those prepared by the once-stacked method. Moreover, the mechanical–microstructure characterization relationships indicated that the compactness of the laminates is higher when the stacked CCF/PPS are separated, which can be explained based on both the void formation and the nanoindentation results. These reinforcements confirm the potential of remodeling the layer-up methods for the development of high-performance carbon fiber-reinforced thermoplastics. This study is of great significance to the improvement of the FDM process and opens broad prospects for the aerospace industry and continuous fiber-reinforced polymer matrix materials.

CubeSat Fabrication through Additive Manufacturing and Micro-Dispensing

2011 ◽  
Vol 2011 (1) ◽  
pp. 001021-001027 ◽  
Author(s):  
Cassie Gutierrez ◽  
Rudy Salas ◽  
Gustavo Hernandez ◽  
Dan Muse ◽  
Richard Olivas ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Computer Aided Design ◽  
Printed Circuit Boards ◽  
Fused Deposition Modeling ◽  
Integrated Approach ◽  
Layer By Layer ◽  
New Paradigm ◽  
Spatial Gradients ◽  
Fused Deposition ◽  
On Demand

Fabricating entire systems with both electrical and mechanical content through on-demand 3D printing is the future for high value manufacturing. In this new paradigm, conformal and complex shapes with a diversity of materials in spatial gradients can be built layer-by-layer using hybrid Additive Manufacturing (AM). A design can be conceived in Computer Aided Design (CAD) and printed on-demand. This new integrated approach enables the fabrication of sophisticated electronics in mechanical structures by avoiding the restrictions of traditional fabrication techniques, which result in stiff, two dimensional printed circuit boards (PCB) fabricated using many disparate and wasteful processes. The integration of Additive Manufacturing (AM) combined with Direct Print (DP) micro-dispensing and robotic pick-and-place for component placement can 1) provide the capability to print-on-demand fabrication, 2) enable the use of micron-resolution cavities for press fitting electronic components and 3) integrate conductive traces for electrical interconnect between components. The fabrication freedom introduced by AM techniques such as stereolithography (SL), ultrasonic consolidation (UC), and fused deposition modeling (FDM) have only recently been explored in the context of electronics integration and 3D packaging. This paper describes a process that provides a novel approach for the fabrication of stiff conformal structures with integrated electronics and describes a prototype demonstration: a volumetrically-efficient sensor and microcontroller subsystem scheduled to launch in a CubeSat designed with the CubeFlow methodology.

Property Enhancement of Carbon Fiber-Reinforced Polylactic Acid Composites Prepared by Fused-Deposition Modeling

2020 ◽  
pp. 455-478
Author(s):  
Pravin R. Kubade ◽  
Hrushikesh B. Kulkarni ◽  
Vinayak C. Gavali
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Carbon Fiber ◽  
Polylactic Acid ◽  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Fiber Reinforced ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Properties Of Composites

Additive Manufacturing or three-dimensional printing refers to a process of building lighter, stronger three-dimensional parts, manufactured layer by layer. Additive manufacturing uses a computer and CAD software which passes the program to the printer to build the desired shape. Metals, thermoplastic polymers, and ceramics are the preferred materials used for additive manufacturing. Fused deposition modeling is one additive manufacturing technique involving the use of thermoplastic polymer for creating desired shape. Carbon fibers can be added into polymer to strengthen the composite without adding additional weight. Present work deals with the manufacturing of Carbon fiber-reinforced Polylactic Acid composites prepared using fused deposition modeling. Mechanical and thermo-mechanical properties of composites are studied as per ASTM standards and using sophisticated instruments. It is observed that there is enhancement in thermo-mechanical properties of composites due to addition reinforcement which is discussed in detail.

Additive manufacturing of carbon fiber-reinforced plastic composites using fused deposition modeling: Effects of process parameters on tensile properties

2016 ◽  
Vol 51 (4) ◽  
pp. 451-462 ◽  
Author(s):  
Fuda Ning ◽  
Weilong Cong ◽  
Yingbin Hu ◽  
Hui Wang
Keyword(s):  
Carbon Fiber ◽  
Fused Deposition Modeling ◽  
Carbon Fiber Reinforced Plastic ◽  
Fiber Reinforced ◽  
Fiber Reinforced Plastic ◽  
Fused Deposition ◽  
Plastic Composites ◽  
Reinforced Plastic ◽  
Deposition Modeling ◽  
Carbon Fiber Reinforced

Carbon fiber-reinforced plastic composites have been intensively used for many applications due to their attractive properties. The increasing demand of carbon fiber-reinforced plastic composites is driving novel manufacturing processes to be in short manufacturing cycle time and low production cost, which is difficult to realize during carbon fiber-reinforced plastic composites fabrication in common molding processes. Fused deposition modeling, as one of the additive manufacturing techniques, has been reported for fabricating carbon fiber-reinforced plastic composites. The process parameters used in fused deposition modeling of carbon fiber-reinforced plastic composites follow those in fused deposition modeling of pure plastic materials. After adding fiber reinforcements, it is crucial to investigate proper fused deposition modeling process parameters to ensure the quality of the carbon fiber-reinforced plastic parts fabricated by fused deposition modeling. However, there are no reported investigations on the effects of fused deposition modeling process parameters on the mechanical properties of carbon fiber-reinforced plastic composites. In the experimental investigations of this paper, carbon fiber-reinforced plastic composite parts are fabricated using a fused deposition modeling machine. Tensile tests are conducted to obtain the tensile properties. The effects of fused deposition modeling process parameters on the tensile properties of fused deposition modeling-fabricated carbon fiber-reinforced plastic composite parts are investigated. The fracture interfaces of the parts after tensile testing are observed by a scanning electron microscope to explain material failure modes and reasons.

scholarly journals Carbon Fiber Reinforced PEEK Composites Based on 3D-Printing Technology for Orthopedic and Dental Applications

2019 ◽  
Vol 8 (2) ◽  
pp. 240 ◽  
Author(s):  
Xingting Han ◽  
Dong Yang ◽  
Chuncheng Yang ◽  
Sebastian Spintzyk ◽  
Lutz Scheideler ◽  
...  
Keyword(s):  
Carbon Fiber ◽  
3D Printing ◽  
Fused Deposition Modeling ◽  
Fiber Reinforced ◽  
Printing Technology ◽  
3D Printing Technology ◽  
Fused Deposition ◽  
Peek Composite ◽  
Carbon Fiber Reinforced ◽  
Mechanical Strengths

Fused deposition modeling (FDM) is a rapidly growing three-dimensional (3D) printing technology and has great potential in medicine. Polyether-ether-ketone (PEEK) is a biocompatible high-performance polymer, which is suitable to be used as an orthopedic/dental implant material. However, the mechanical properties and biocompatibility of FDM-printed PEEK and its composites are still not clear. In this study, FDM-printed pure PEEK and carbon fiber reinforced PEEK (CFR-PEEK) composite were successfully fabricated by FDM and characterized by mechanical tests. Moreover, the sample surfaces were modified with polishing and sandblasting methods to analyze the influence of surface roughness and topography on general biocompatibility (cytotoxicity) and cell adhesion. The results indicated that the printed CFR-PEEK samples had significantly higher general mechanical strengths than the printed pure PEEK (even though there was no statistical difference in compressive strength). Both PEEK and CFR-PEEK materials showed good biocompatibility with and without surface modification. Cell densities on the “as-printed” PEEK and the CFR-PEEK sample surfaces were significantly higher than on the corresponding polished and sandblasted samples. Therefore, the FDM-printed CFR-PEEK composite with proper mechanical strengths has potential as a biomaterial for bone grafting and tissue engineering applications.

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