Additive Layer Manufacturing of Carbon Fiber/PEKK Composites for Aeronautic Application

Abstract

A 3d printer has been prototyped for additive manufacturing of carbon fiber (CF) poly-ether-ketone-ketone (PEKK) composites. The machine consisted of a SCARA robot, equipped with an extrusion device. The nozzle was designed to allow the deposition of thin unidirectional (UD) tapes without affecting the fiber continuity. An elastic connection between the robot end-effector and the extruder was used for allowing tape agglomeration during manufacturing. Deposition tests were carried out at the extrusion temperature of 400°C and the rate of 130 mm/min, for a maximum number of 3 layers on a CF-epoxy laminate as substrate. The good agglomeration of the 3d printed parts and their adhesion on the composite substrate are shown by the resulted final thickness, and the ability to machine them by end milling. Results show the feasibility of using this technology for the manufacturing of composite shims in the aeronautic sector.