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Journal ArticleDOI

Fabrication of Continuous Carbon, Glass and Kevlar fibre reinforced polymer composites using Additive Manufacturing

01 Aug 2017-Additive manufacturing (Elsevier)-Vol. 16, pp 146-152
TL;DR: In this paper, the performance of continuous carbon, Kevlar and glass fibre reinforced composites manufactured using the fused deposition modelling (FDM) additive manufacturing technique was evaluated both in tension and flexure.
Abstract: This study evaluates the performance of continuous carbon, Kevlar and glass fibre reinforced composites manufactured using the fused deposition modelling (FDM) additive manufacturing technique. The fibre reinforced nylon composites were fabricated using a Markforged Mark One 3D printing system. The mechanical performance of the composites was evaluated both in tension and flexure. The influence of fibre orientation, fibre type and volume fraction on mechanical properties were also investigated. The results were compared with that of both non-reinforced nylon control specimens, and known material property values from literature. It was demonstrated that of the fibres investigated, those fabricated using carbon fibre yielded the largest increase in mechanical strength per fibre volume. Its tensile strength values were up to 6.3 times higher than those obtained with the non-reinforced nylon polymer. As the carbon and glass fibre volume fraction increased so too did the level of air inclusion in the composite matrix, which impacted on mechanical performance. As a result, a maximum efficiency in tensile strength was observed in glass specimen as fibre content approached 22.5%, with higher fibre contents (up to 33%), yielding only minor increases in strength.
Citations
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Journal ArticleDOI
TL;DR: In this paper, a detailed summary of mechanical properties of printed parts for different composite material systems is presented and discussed, including the flow and resulting fiber orientation, the bond formation between adjacent beads and the thermomechanical solidification behavior of the deposited material.
Abstract: Recent advancements in the Additive Manufacturing (AM) Fused Filament Fabrication (FFF) approach are described with focus on the application to tooling and molds for composite materials and structures. A detailed summary of mechanical properties of printed parts for different composite material systems is presented and discussed. These material systems are comprised of discontinuous fiber-reinforced polymers characterized by fiber orientation dominantly parallel to the direction of the extrudate. An overview of the FFF process and its physical phenomena is given including the flow and resulting fiber orientation, the bond formation between adjacent beads and the thermomechanical solidification behavior of the deposited material. Based on reviewed research in these different phenomena, future research needs are discussed and desirable objectives are formulated.

457 citations

Journal ArticleDOI
TL;DR: In this paper, the surface treatment of carbon fibers is employed to increase the surface functional groups and interfacial adhesion between the CFs and the surrounding polymer matrix, and the thermal, mechanical, and electrical properties of the composites are also discussed.
Abstract: Carbon fibers (CFs) have high specific tensile strength, high modulus, and outstanding wear resistance, and are widely used for the reinforcement of advanced composite materials. CF-reinforced thermoplastic composites have received much attention because of their easy processability and recycling convenience compared with thermosetting composites. Surface treatment of CFs is generally employed to increase the surface functional groups and interfacial adhesion between the CFs and the surrounding polymer matrix. In this review, we explore recent advances in the surface treatment of CFs and preparation of CF/thermoplastic composites. The thermal, mechanical, and electrical properties of the composites are also discussed.

438 citations


Cites background or methods from "Fabrication of Continuous Carbon, G..."

  • ...The PA and fiber layers were printed onto a print bed using a hot end temperature of 263 °C [61]....

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  • ...[61] investigated the influence of the fiber orientation, fiber type, and volume fraction on the mechanical properties of continuous CF-reinforced PA composites....

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Journal ArticleDOI
10 Jul 2020-Polymers
TL;DR: The most common defects on printed parts, in particular the void formation, surface roughness and poor bonding between fibre and matrix, are explored and an inclusive discussion on the effectiveness of chemical, laser, heat and ultrasound treatments to minimize these drawbacks is provided.
Abstract: Fused deposition modelling (FDM) is one of the fastest-growing additive manufacturing methods used in printing fibre-reinforced composites (FRC). The performances of the resulting printed parts are limited compared to those by other manufacturing methods due to their inherent defects. Hence, the effort to develop treatment methods to overcome these drawbacks has accelerated during the past few years. The main focus of this study is to review the impact of those defects on the mechanical performance of FRC and therefore to discuss the available treatment methods to eliminate or minimize them in order to enhance the functional properties of the printed parts. As FRC is a combination of polymer matrix material and continuous or short reinforcing fibres, this review will thoroughly discuss both thermoplastic polymers and FRCs printed via FDM technology, including the effect of printing parameters such as layer thickness, infill pattern, raster angle and fibre orientation. The most common defects on printed parts, in particular, the void formation, surface roughness and poor bonding between fibre and matrix, are explored. An inclusive discussion on the effectiveness of chemical, laser, heat and ultrasound treatments to minimize these drawbacks is provided by this review.

355 citations

References
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Journal ArticleDOI
TL;DR: In this paper, the authors give an overview on 3D printing techniques of polymer composite materials and the properties and performance of 3D printed composite parts as well as their potential applications in the fields of biomedical, electronics and aerospace engineering.
Abstract: The use of 3D printing for rapid tooling and manufacturing has promised to produce components with complex geometries according to computer designs. Due to the intrinsically limited mechanical properties and functionalities of printed pure polymer parts, there is a critical need to develop printable polymer composites with high performance. 3D printing offers many advantages in the fabrication of composites, including high precision, cost effective and customized geometry. This article gives an overview on 3D printing techniques of polymer composite materials and the properties and performance of 3D printed composite parts as well as their potential applications in the fields of biomedical, electronics and aerospace engineering. Common 3D printing techniques such as fused deposition modeling, selective laser sintering, inkjet 3D printing, stereolithography, and 3D plotting are introduced. The formation methodology and the performance of particle-, fiber- and nanomaterial-reinforced polymer composites are emphasized. Finally, important limitations are identified to motivate the future research of 3D printing.

2,132 citations

Journal ArticleDOI
TL;DR: In this article, a carbon fiber reinforced plastic (CFRP) composite is used for Fused Deposition Modeling (FDM) of thermoplastic matrix CFRP composites.
Abstract: Additive manufacturing (AM) technologies have been successfully applied in various applications. Fused deposition modeling (FDM), one of the most popular AM techniques, is the most widely used method for fabricating thermoplastic parts those are mainly used as rapid prototypes for functional testing with advantages of low cost, minimal wastage, and ease of material change. Due to the intrinsically limited mechanical properties of pure thermoplastic materials, there is a critical need to improve mechanical properties for FDM-fabricated pure thermoplastic parts. One of the possible methods is adding reinforced materials (such as carbon fibers) into plastic materials to form thermoplastic matrix carbon fiber reinforced plastic (CFRP) composites those could be directly used in the actual application areas, such as aerospace, automotive, and wind energy. This paper is going to present FDM of thermoplastic matrix CFRP composites and test if adding carbon fiber (different content and length) can improve the mechanical properties of FDM-fabricated parts. The CFRP feedstock filaments were fabricated from plastic pellets and carbon fiber powders for FDM process. After FDM fabrication, effects on the tensile properties (including tensile strength, Young's modulus, toughness, yield strength, and ductility) and flexural properties (including flexural stress, flexural modulus, flexural toughness, and flexural yield strength) of specimens were experimentally investigated. In order to explore the parts fracture reasons during tensile and flexural tests, fracture interface of CFRP composite specimens after tensile testing and flexural testing was observed and analyzed using SEM micrograph.

1,133 citations

Journal ArticleDOI
TL;DR: In this paper, the authors investigated the short fiber (02 mm to 04 mm) reinforced acrylonitrile-butadiene-styrene composites as a feedstock for 3D-printing in terms of their processibility, microstructure and mechanical performance.

1,016 citations

Journal ArticleDOI
TL;DR: The technique enables direct 3D fabrication without the use of molds and may become the standard next-generation composite fabrication methodology.
Abstract: We have developed a method for the three-dimensional (3D) printing of continuous fiber-reinforced thermoplastics based on fused-deposition modeling. The technique enables direct 3D fabrication without the use of molds and may become the standard next-generation composite fabrication methodology. A thermoplastic filament and continuous fibers were separately supplied to the 3D printer and the fibers were impregnated with the filament within the heated nozzle of the printer immediately before printing. Polylactic acid was used as the matrix while carbon fibers, or twisted yarns of natural jute fibers, were used as the reinforcements. The thermoplastics reinforced with unidirectional jute fibers were examples of plant-sourced composites; those reinforced with unidirectional carbon fiber showed mechanical properties superior to those of both the jute-reinforced and unreinforced thermoplastics. Continuous fiber reinforcement improved the tensile strength of the printed composites relative to the values shown by conventional 3D-printed polymer-based composites.

722 citations

Journal ArticleDOI
TL;DR: In this article, an analytical method considering the effects of fiber length and fiber orientation distributions for predicting the tensile strength of short-fiber-reinforced polymers (SFRP) was presented.

685 citations