Abstract:Additive manufacturing (AM) provides many benefits such as reduced manufacturing lead times, streamlined supply chains, part consolidation, structural optimisation and improved buyto-fly ratios. Barriers to adoption include high material and processing costs, low build rates, isotropic material properties, and variable processing conditions. Currently AM polymer parts are far less expensive to manufacture than AM metal parts, therefore improving the properties of polymer parts is highly desirable. This paper introduces a design methodology used to integrate continuous reinforcement into AM polymer parts with the aim of improving their mechanical properties. The method is validated with the design and testing of three case studies, a pulley housing, hook and universal joint used to demonstrate the applicability of the method for tensile, bending and torsion loading types respectively.Physical testing showed that it was possible to improve the strength of parts by over 4000%,

This paper introduces a design methodology used to integrate continuous fibre reinforcement into AM polymer parts with the aim of improving their mechanical properties. Tensile and low cycle fatigue testing of reinforced parts is carried out for a range of load conditions and strain rates Physical testing showed that it was possible to improve the strength of parts by 400% and cycles to failure by 42,800% with the addition of 4% carbon by weight. Logarithmic load/cycle relationships were found also samples showed significant variability in the number of cycles to failure. No correlation between the density of the polylactic acid (PLA) infill and the tensile strength or low cycle fatigue life.Access holes used to thread the fibre into the reinforcement channels were identified as stress concentrators initiating cracks in the PLA and separation of the reinforcement from the PLA part.

This paper introduces a design methodology used to integrate continuous fibre reinforcement into AM polymer parts with the aim of improving their mechanical properties. Tensile and low cycle fatigue testing of reinforced parts is carried out for a range of load conditions and strain rates Physical testing showed that it was possible to improve the strength of parts by 400% and cycles to failure by 42,800% with the addition of 4% carbon by weight. Logarithmic load/cycle relationships were found also samples showed significant variability in the number of cycles to failure. No correlation between the density of the polylactic acid (PLA) infill and the tensile strength or low cycle fatigue life. Access holes used to thread the fibre into the reinforcement channels were identified as stress concentrators initiating cracks in the PLA and separation of the reinforcement from the PLA part.