General rightsThis document is made available in accordance with publisher policies. Please cite only the published version using the reference above. Full terms of use are available: http://www.bristol.ac.uk/pure/about/ebr-terms A B S T R A C TFused filament fabrication (FFF) is a 3D printing technique which allows layer-by-layer build-up of a part by the deposition of thermoplastic material through a nozzle. The technique allows for complex shapes to be made with a degree of design freedom unachievable with traditional manufacturing methods. However, the mechanical properties of the thermoplastic materials used are low compared to common engineering materials. In this work, composite 3D printing feedstocks for FFF are investigated, wherein carbon fibres are embedded into a thermoplastic matrix to increase strength and stiffness. First, the key processing parameters for FFF are reviewed, showing how fibres alter the printing dynamics by changing the viscosity and the thermal profile of the printed material. The state-of-the-art in composite 3D printing is presented, showing a distinction between short fibre feedstocks versus continuous fibre feedstocks. An experimental study was performed to benchmark these two methods. It is found that printing of continuous carbon fibres using the MarkOne printer gives significant increases in performance over unreinforced thermoplastics, with mechanical properties in the same order of magnitude of typical unidirectional epoxy matrix composites. The method, however, is limited in design freedom as the brittle continuous carbon fibres cannot be deposited freely through small steering radii and sharp angles. Filaments with embedded short carbon microfibres (∼100 μm) show better print capabilities and are suitable for use with standard printing methods, but only offer a slight increase in mechanical properties over the pure thermoplastic properties. It is hypothesized that increasing the fibre length in short fibre filament is expected to lead to increased mechanical properties, potentially approaching those of continuous fibre composites, whilst keeping the high degree of design freedom of the FFF process.

The aim of this research is to manufacture intermingled hybrid composites using aligned discontinuous fibres to achieve pseudo-ductility. Hybrid composites, made with different types of fibres that provide a balanced suite of modulus, strength and ductility, allow avoiding catastrophic failure that is a key limitation of composites. Two different material combinations of high strength carbon/E-glass and high modulus carbon/E-glass were selected. Several highly aligned and well dispersed short fibre hybrid composites with different carbon/glass ratios were manufactured and tested in tension in order to investigate the carbon ratio effect on the stress-strain curve. Good pseudo-ductile responses were obtained from the high modulus carbon/E-glass composites due to the fragmentation of the carbon fibres. The experimental results were also compared with an analytical solution. The intermingled hybrid composite with 0.25 relative carbon ratio gave the maximum pseudo-ductile strain, 1.1%, with a 110 GPa tensile modulus. Moreover, the initial modulus of the intermingled hybrids with 0.4 relative carbon ratio is 134 GPa, 3.5 times higher than that of E-glass/epoxy composites. The stress-strain curve shows a clear "yield point" at 441 MPa and a well dispersed and gradual damage process

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The feasibility of using the HiPerDiF (high performance discontinuous fibre) method to manufacture highly aligned discontinuous fibres intermingled hybrid composites with flax and reclaimed carbon fibres (rCF), and the potential benefits of so doing, are investigated in this paper. It is demonstrated that, despite their hydrophilic nature, flax fibres are not affected by this water-based process. Intermingled flax/rCF hybrid composites are characterised in terms of their tensile and vibrational response. It is concluded that natural/rCF fibre hybrid composites can be a viable solution for those applications where a reduction in primary mechanical properties, e.g., stiffness and strength, is an acceptable trade-off for the enhancement of secondary properties, e.g., noise, vibration, and harshness (NVH) mitigation, and the reduction of monetary costs.

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