Additive manufacturing of continuous carbon fiber reinforced polyamide 6: The effect of process parameters on the microstructure and mechanical properties

Oberlercher, Hannes; Heim, R.; Laux, M.; Berndt, Alexander; Becker, Clarissa; Amancio‐Filho, Sergio T.; Riemelmoser, F. O.

doi:10.1016/j.prostr.2021.12.017

Cited by 5 publications

(4 citation statements)

References 7 publications

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“…Most research studies about the additive manufacturing of thermoplastic polymers are focused on the analysis of FDM producibility parameters [25][26][27]. However, additive manufacturing technology presents some limitations for the fabrication of large moulds [28].…”

Section: Introductionmentioning

confidence: 99%

“…Most studies regarding engineeringgrade polyamide 6 reinforced with carbon fibre (PA6/CF) are focused on the analysis of FDM producibility parameters. In this sense, the material properties of PA6/CF highly depend on the material form, CF content, manufacturing process and corresponding parameters [26,[41][42][43][44] being available at room temperature upon request. For example, Table 1 shows the relevant mechanical properties at room temperature of two different polyamides reinforced with 20% carbon fibre after different processing methods.…”

Section: Introductionmentioning

confidence: 99%

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Experimental Characterization of Screw-Extruded Carbon Fibre-Reinforced Polyamide: Design for Aeronautical Mould Preforms with Multiphysics Computational Guidance

Antolin-Urbaneja,

Vallejo Artola,

Bellvert Rios

et al. 2024

JMMP

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In this research work, the suitability of short carbon fibre-reinforced polyamide 6 in pellet form for printing an aeronautical mould preform with specific thermomechanical requirements is investigated. This research study is based on an extensive experimental characterization campaign, in which the principal mechanical properties of the printed material are determined. Furthermore, the temperature dependency of the material properties is characterized by testing samples at different temperatures for bead printing and stacking directions. Additionally, the thermal properties of the material are characterized, including the coefficient of thermal expansion. Moreover, the influence of printing machine parameters is evaluated by comparing the obtained tensile moduli and strengths of several manufactured samples at room temperature. The results show that the moduli and strengths can vary from 78% to 112% and from 55% to 87%, respectively. Based on a real case study of its aeronautical use and on the experimental data from the characterization stage, a new mould design is iteratively developed with multiphysics computational guidance, considering 3D printing features and limitations. Specific design drivers are identified from the observed material’s thermomechanical performance. The designed mould, whose mass is reduced around 90% in comparison to that of the original invar design, is numerically proven to fulfil thermal and mechanical requirements with a high performance.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Experimental Characterization of Screw-Extruded Carbon Fibre-Reinforced Polyamide: Design for Aeronautical Mould Preforms with Multiphysics Computational Guidance

Antolin-Urbaneja,

Vallejo Artola,

Bellvert Rios

et al. 2024

JMMP

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“…In a preliminary investigation, the influence of consolidation in 3D printing of CFC was shown. It has been found that increasing the contact pressure on the molten filament can lead to a reduction in voids in the laminate and an improvement in mechanical properties [3][4][5][6].…”

Section: Introductionmentioning

confidence: 99%

In-situ consolidation of additively manufactured continuous fiber reinforced material: Technical approach and results

Oberlercher

2023

Materials Research Proceedings

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Abstract. Additive manufacturing (AM) of continuous fiber reinforced composites (CFC) is becoming increasingly important in the field of lightweight construction. The major advantage lies particular in the automated manufacturing process and in the production of complex geometries. Most work was done with traditional fusion filament fabrication (FFF) and the lack of separate consolidation units. AM CFCs produced in this manner have shown increased consolidation-related volumetric flaws -i.e. deconsolidation defects decreasing mechanical performance. The presence of deconsolidation defects, normally indicates either poor process parameters selection or inadequate in situ consolidation. Recently, there were several efforts in modifying the FFF of CFCs to minimize deconsolidation defects through in situ thermo-mechanical pressing. However, there are only limited fundamental knowledge on the in situ thermo-mechanical consolidation of FFF-CFCs. The present paper analyses the stated problem and proposes ways to decrease deconsolidation in FFF CF-PA6 laminates. For this purpose, we used a self-developed FFF 3D Printer coupled with a thermo-mechanical pressing unit. The influence of extrusion-, consolidation temperature, printing speed and in situ consolidation pressure on laminate microstructure and flexural strength was investigated. A comparison with FFF laminates printed in a common 3D printer was performed. The controlled 3D printing consolidation process leads to a homogeneous distribution of fibers in the matrix material and to an improvement of the material parameters of the reinforcing composite.

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“…The high potential of this new composite manufacturing technology has also attracted the research community in recent years. To date, there are several studies on 3D-printed composites in the literature, most of which report mechanical characterizations of composites made with commercial 3D printers (generally, as a function of printing parameters) [11,14,15]. However, it is evident that most of the criticalities highlighted are related to hardware and software limitations of commercial printers.…”

Section: Introductionmentioning

confidence: 99%

Development of a 3D printer optimized for rapid prototyping with continuous fiber fabrication technology

Benvenuto

2023

Materials Research Proceedings

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Abstract. In the industrial field, Additive Manufacturing is a production concept that is increasingly gaining ground. The secret of its success lies in its definition: being able to produce an object by the progressive deposition of material instead of its removal as for the traditional machining. In this way, problems such as waste quantities, complex geometries and machining changes are greatly reduced, making these processes particularly useful and effective for rapid prototyping and the production of small series of objects. This experimental work examines the changes made to a 3D printer initially set up for the use of polymeric materials with Fused Deposition Modelling technology. Going into more detail, this machine was modified in a manner that would make it compatible with the introduction of polymer filaments reinforced with continuous carbon fiber according to the main principles of Continuous Fiber Fabrication technology. The changes made also involved electronics and informatics so that the printer could be easily operated through the platform.

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Additive manufacturing of continuous carbon fiber reinforced polyamide 6: The effect of process parameters on the microstructure and mechanical properties

Cited by 5 publications

References 7 publications

Experimental Characterization of Screw-Extruded Carbon Fibre-Reinforced Polyamide: Design for Aeronautical Mould Preforms with Multiphysics Computational Guidance

Experimental Characterization of Screw-Extruded Carbon Fibre-Reinforced Polyamide: Design for Aeronautical Mould Preforms with Multiphysics Computational Guidance

In-situ consolidation of additively manufactured continuous fiber reinforced material: Technical approach and results

Development of a 3D printer optimized for rapid prototyping with continuous fiber fabrication technology

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