A Novel Approach: Combination of Automated Fiber Placement (AFP) and Additive Layer Manufacturing (ALM)

Rakhshbahar, Mohammad; Sinapius, Michael

doi:10.3390/jcs2030042

Cited by 33 publications

(16 citation statements)

References 10 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Thus, highly durable functional parts for the automotive industry could be produced with material extrusion in the future. In aircraft manufacturing, it is expected that this additive manufacturing process combined with automated tape laying (ATL) can repair defects in large fiber composite structures [ 44 ]. This can significantly reduce repair and maintenance costs in this field.…”

Section: Discussionmentioning

confidence: 99%

Development and Processing of Continuous Flax and Carbon Fiber-Reinforced Thermoplastic Composites by a Modified Material Extrusion Process

et al. 2021

View full text Add to dashboard Cite

Additive manufacturing, especially material extrusion (MEX), has received a lot of attention recently. The reasons for this are the numerous advantages compared to conventional manufacturing processes, which result in various new possibilities for product development and -design. By applying material layer by layer, parts with complex, load-path optimized geometries can be manufactured at neutral costs. To expand the application fields of MEX, high-strength and simultaneously lightweight materials are required which fulfill the requirements of highly resilient technical parts. For instance, the embedding of continuous carbon and flax fibers in a polymer matrix offers great potential for this. To achieve the highest possible variability with regard to the material combinations while ensuring simple and economical production, the fiber–matrix bonding should be carried out in one process step together with the actual parts manufacture. This paper deals with the adaptation and improvement of the 3D printer on the one hand and the characterization of 3D printed test specimens based on carbon and flax fibers on the other hand. For this purpose, the print head development for in-situ processing of contin uous fiber-reinforced parts with improved mechanical properties is described. It was determined that compared to neat polylactic acid (PLA), the continuous fiber-reinforced test specimens achieve up to 430% higher tensile strength and 890% higher tensile modulus for the carbon fiber reinforcement and an increase of up to 325% in tensile strength and 570% in tensile modulus for the flax fibers. Similar improvements in performance were achieved in the bending tests.

show abstract

Section: Discussionmentioning

confidence: 99%

Development and Processing of Continuous Flax and Carbon Fiber-Reinforced Thermoplastic Composites by a Modified Material Extrusion Process

et al. 2021

View full text Add to dashboard Cite

show abstract

“…Fiber material and filament are transported by different systems and joined together in the printing head. In contrast to conventional printing filaments, the carbon fiber filament has to be cut after printing [13]. A combined feeding and cutting unit can also be integrated for 3D printing with continuous carbon fiber.…”

Section: Methodsmentioning

confidence: 99%

Adaptive Feeding Roller with An Integrated Cutting System for Automated Fiber Placement (AFP)

Bahar

Sinapius

2020

J. Compos. Sci.

Self Cite

View full text Add to dashboard Cite

Automated Fiber Placement (AFP) has been used for more than 30 years as a manufacturing process for large components such as aircraft fuselage or nose made of composite materials. As the literature research showed, 85% of efficient AFP head process time is used for the cutting process, accelerating, decelerating and necessary directional changes of the AFP head. The AFP head consists of various modules that synchronize the complete process. In recent years, scientists tried to extend the advantages of this technique and optimize the process. The aim of this article is to show the integration of the cutting unit and the feeding unit in a compact and simple system. Therefore the cutting edge of the tape and the productivity can be increased significantly. The feeding system pulls the tape from the material spool to under the compaction roller. Obviously, the tape should also cut to a predefined length. According to the state of the art, the cutting unit works when the feeding unit is in the standing position. The layup process has therefore a short break, which is no longer required with the new approach. The cutting process is realized without interruption, therefore the lost time during cutting can be saved. The integrated unit is synchronized with the AFP process to apply the active or passive feeding process.

show abstract

“…Corresponding testing guidelines or standards specify the specimen geometry, layup, test fixture and procedure on material and laminate level exactly. Some research groups [56,57,72,78,79] quantify the effects of gaps and overlaps on material and laminate level. Faló et al [73,74] experimentally investigate the damage tolerance of unconventional laminates.…”

Section: Type Iv-gap and Overlapmentioning

confidence: 99%

Manufacturing-Induced Imperfections in Composite Parts Manufactured via Automated Fiber Placement

2019

View full text Add to dashboard Cite

The automated fiber placement process (AFP) enables the manufacturing of large and geometrical complex fiber composite structures with high quality at low cycle times. Although the AFP process is highly accurate and reproducible, manufacturing induced imperfections in the produced composite structure occur. This review summarizes and classifies typical AFP-related manufacturing defects. Several methodologies for evaluating the effects of such manufacturing defects from the literature are reviewed. This review paper presents recent scientific contributions and discusses proposed experimental and simulation-based methodologies. Among the identified ten defect classes, gaps and overlaps are predominant. This paper focuses then on methods for modelling and assessing gaps and overlaps. The state of the art in modelling gaps and overlaps and assessing their influence on mechanical properties is presented. Finally, research gaps and remaining issues are identified.

show abstract

A Novel Approach: Combination of Automated Fiber Placement (AFP) and Additive Layer Manufacturing (ALM)

Cited by 33 publications

References 10 publications

Development and Processing of Continuous Flax and Carbon Fiber-Reinforced Thermoplastic Composites by a Modified Material Extrusion Process

Development and Processing of Continuous Flax and Carbon Fiber-Reinforced Thermoplastic Composites by a Modified Material Extrusion Process

Adaptive Feeding Roller with An Integrated Cutting System for Automated Fiber Placement (AFP)

Manufacturing-Induced Imperfections in Composite Parts Manufactured via Automated Fiber Placement

Contact Info

Product

Resources

About