scholarly journals Fused Filament Fabrication of Polymers and Continuous Fiber-Reinforced Polymer Composites: Advances in Structure Optimization and Health Monitoring

Polymers ◽  
2021 ◽  
Vol 13 (5) ◽  
pp. 789
Author(s):  
Fatemeh Mashayekhi ◽  
Julien Bardon ◽  
Vincent Berthé ◽  
Henri Perrin ◽  
Stephan Westermann ◽  
...  
Keyword(s):  
Health Monitoring ◽  
Thermoplastic Composites ◽  
Fiber Reinforced ◽  
Continuous Fiber ◽  
Fused Filament Fabrication ◽  
Thermoplastic Matrix ◽  
Fiber Reinforced Polymer Composites ◽  
3D Printed ◽  
Printed Materials ◽  
Monitoring Technologies

3D printed neat thermoplastic polymers (TPs) and continuous fiber-reinforced thermoplastic composites (CFRTPCs) by fused filament fabrication (FFF) are becoming attractive materials for numerous applications. However, the structure of these materials exhibits interfaces at different scales, engendering non-optimal mechanical properties. The first part of the review presents a description of these interfaces and highlights the different strategies to improve interfacial bonding. The actual knowledge on the structural aspects of the thermoplastic matrix is also summarized in this contribution with a focus on crystallization and orientation. The research to be tackled to further improve the structural properties of the 3D printed materials is identified. The second part of the review provides an overview of structural health monitoring technologies relying on the use of fiber Bragg grating sensors, strain gauge sensors and self-sensing. After a brief discussion on these three technologies, the needed research to further stimulate the development of FFF is identified. Finally, in the third part of this contribution the technology landscape of FFF processes for CFRTPCs is provided, including the future trends.

Stiffness prediction of 3D printed fiber-reinforced thermoplastic composites

2019 ◽  
Vol 26 (3) ◽  
pp. 549-555
Author(s):  
Jin Young Choi ◽  
Mark Timothy Kortschot
Keyword(s):  
Mechanical Properties ◽  
Extrusion Direction ◽  
Analytical Models ◽  
Thermoplastic Composites ◽  
Fiber Reinforced ◽  
Flat Plates ◽  
Fused Filament Fabrication ◽  
Element Analysis ◽  
Content Type ◽  
3D Printed

Purpose The purpose of this study is to confirm that the stiffness of fused filament fabrication (FFF) three-dimensionally (3D) printed fiber-reinforced thermoplastic (FRP) materials can be predicted using classical laminate theory (CLT), and to subsequently use the model to demonstrate its potential to improve the mechanical properties of FFF 3D printed parts intended for load-bearing applications. Design/methodology/approach The porosity and the fiber orientation in specimens printed with carbon fiber reinforced filament were calculated from micro-computed tomography (µCT) images. The infill portion of the sample was modeled using CLT, while the perimeter contour portion was modeled with a rule of mixtures (ROM) approach. Findings The µCT scan images showed that a low porosity of 0.7 ± 0.1% was achieved, and the fibers were highly oriented in the filament extrusion direction. CLT and ROM were effective analytical models to predict the elastic modulus and Poisson’s ratio of FFF 3D printed FRP laminates. Research limitations/implications In this study, the CLT model was only used to predict the properties of flat plates. Once the in-plane properties are known, however, they can be used in a finite element analysis to predict the behavior of plate and shell structures. Practical implications By controlling the raster orientation, the mechanical properties of a FFF part can be optimized for the intended application. Originality/value Before this study, CLT had not been validated for FFF 3D printed FRPs. CLT can be used to help designers tailor the raster pattern of each layer for specific stiffness requirements.

Process evaluation, tensile properties, mathematical models, and fracture behavior of 3D printed continuous fiber reinforced thermoplastic composites

2021 ◽  
pp. 073168442110160
Author(s):  
Wei Chen ◽  
Qiuju Zhang ◽  
Han Cao ◽  
Ye Yuan
Keyword(s):  
Elastic Modulus ◽  
Mathematical Models ◽  
Tensile Properties ◽  
Fracture Behavior ◽  
Thermoplastic Composites ◽  
Fiber Reinforced ◽  
Continuous Fiber ◽  
3D Printed ◽  
Central Mode ◽  
Relative Errors

Continuous fiber reinforced thermoplastic composites with advantages of high strength, long life, corrosion resistance, and green recyclability have been widely used in aerospace, transportation and high-precision processing equipment, etc. 3D printing is an advanced additive manufacturing technology that enables the rapid manufacture of complex structures and high-performance composites. The aim of this study is to evaluate the precision and stability of 3D printed continuous fiber reinforced thermoplastic composite structures and construct suitable mathematical models to predict tensile properties. Samples evaluated in this study were produced by varying the volume fraction and distribution mode (average and central mode) of fibers within the printed structures. The measured data proved the continuous fiber reduced the printing precision on width and thickness and the printing stability on thickness, while it improved the width stability in the XY horizontal plane. The printing precision and stability of samples with an average mode were slightly better than those of samples with a central mode. The tensile results of 3D printed continuous fiber reinforced thermoplastic composites demonstrated that an increasing volume of fiber reinforcement resulted in the increasing stiffness and ultimate strength of tested samples. The average elastic modulus and ultimate tensile strength of samples with the average mode were higher than those of samples with the central mode, while the average strain at break was quite the opposite. Mathematical models of elastic modulus were established to achieve the relative errors 0.06% and 2.14% for checked samples, while relative errors of the mixing rule were up to 76.15% and 81.71%, respectively. Some typical defects affecting the surface quality and the fracture behavior of 3D printed samples were researched by the analysis of micromorphology.

scholarly journals A Continuous Fiber-Reinforced Additive Manufacturing Processing Based on PET Fiber and PLA

Materials ◽  
2020 ◽  
Vol 13 (14) ◽  
pp. 3044
Author(s):  
Yuan Yao ◽  
Meng Li ◽  
Maximilian Lackner ◽  
Lammer Herfried
Keyword(s):  
Mechanical Tests ◽  
Thermoplastic Composites ◽  
Fiber Reinforced ◽  
Continuous Fiber ◽  
Polyamide 66 ◽  
Fused Filament Fabrication ◽  
Planning Strategy ◽  
Material Recycling ◽  
Material Recovery ◽  
Toolpath Planning

Continuous fiber-reinforced manufacturing has many advantages, but the fabrication cost is high and its process is difficult to control. This paper presents a method for printing fiber-reinforced composite on the common fused filament fabrication (FFF) platform. Polylactic Acid (PLA) and Polyethylene terephthalate (PET) fibers are used as printing materials. A spatial continuous toolpath planning strategy is employed to reduce the workload of post-processing without cutting the fiber. Experimental results show that this process not only enables the printing of models with complex geometric shapes but also supports material recycling and reuse. A material recovery rate of 100% for continuous PET fiber and 83% for PLA were achieved for a better environmental impact. Mechanical tests show that the maximum tensile strength of continuous PET fiber-reinforced thermoplastic composites (PFRTPCs) is increased by 117.8% when compared to polyamide-66 (PA66).

scholarly journals Three-Dimensional Printing of Continuous Flax Fiber-Reinforced Thermoplastic Composites by Five-Axis Machine

Materials ◽  
2020 ◽  
Vol 13 (7) ◽  
pp. 1678 ◽  
Author(s):  
Haiguang Zhang ◽  
Di Liu ◽  
Tinglong Huang ◽  
Qingxi Hu ◽  
Herfried Lammer
Keyword(s):  
Natural Fiber ◽  
Three Dimensional ◽  
Flax Fiber ◽  
Thermoplastic Composites ◽  
3D Printer ◽  
Fiber Reinforced ◽  
Fused Filament Fabrication ◽  
Reinforced Plastic ◽  
3D Printed ◽  
Five Axis

A method for printing continuous flax fiber-reinforced plastic (CFFRP) composite parts by five-axis three-dimensional (3D) printer, based on fused filament fabrication (FFF) technology, has been developed. FFF printed parts usually need supporting structures, have a stair step effect, and unfavorable mechanical properties. In order to address these deficiencies, continuous natural fiber prepreg filaments were first manufactured, followed by curved path planning for the model for generation of the G-code, and finally printed by a five-axis 3D printer. The surface quality of printed parts was greatly improved. The tensile strength and modulus of CFFRP increased by 89% and 73%, respectively, compared with polylactic acid (PLA) filaments. The flexural strength and modulus of the 3D-printed CFFRP specimens increased by 211% and 224%, respectively, compared with PLA specimens. The maximal curved bending force load and stiffness of the 3D-printed CFFRP specimens increased by 39% and 115%, respectively, compared with the flat slicing method. Advanced light structures, such as leaf springs, can be designed and manufactured by taking advantage of the favorable properties of these composites, which endow them with significant potential for application in the field of automobiles.

Impacts of thermoplastics content on mechanical properties of continuous fiber-reinforced thermoplastic composites

2021 ◽  
Vol 216 ◽  
pp. 108859
Author(s):  
Dong-Jun Kwon ◽  
Neul-Sae-Rom Kim ◽  
Yeong-Jin Jang ◽  
Hyun Ho Choi ◽  
Kihyun Kim ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Thermoplastic Composites ◽  
Fiber Reinforced ◽  
Continuous Fiber
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