Additive manufacturing of polymer composites: Processing and modeling approaches

Moumen, Aziz; Tarfaoui, Mostapha; Lafdi, Khalid

doi:10.1016/j.compositesb.2019.04.029

Cited by 140 publications

(65 citation statements)

References 148 publications

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“…Depending on the necessity, particles, fibres or nanomaterial can be added to the polymer to print a polymer matrix composite (PMC). The most popular PMCs are micro- or nano-particle reinforced composites, metal particle reinforced composites and short or continuous fibre-reinforced composites [ 101 , 102 , 103 , 104 ]. By adding metal particles such as iron, copper, stainless-steel, titanium or nanoparticles such as carbon nanotubes, graphene or graphite to the polymer, a high-performance composite with embedded thermal, electrical, optical and excellent mechanical properties could be developed [ 105 , 106 , 107 , 108 , 109 , 110 , 111 , 112 , 113 , 114 , 115 , 116 ].…”

Section: Fibre-reinforced Composite Printingmentioning

confidence: 99%

FDM-Based 3D Printing of Polymer and Associated Composite: A Review on Mechanical Properties, Defects and Treatments

2020

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Fused deposition modelling (FDM) is one of the fastest-growing additive manufacturing methods used in printing fibre-reinforced composites (FRC). The performances of the resulting printed parts are limited compared to those by other manufacturing methods due to their inherent defects. Hence, the effort to develop treatment methods to overcome these drawbacks has accelerated during the past few years. The main focus of this study is to review the impact of those defects on the mechanical performance of FRC and therefore to discuss the available treatment methods to eliminate or minimize them in order to enhance the functional properties of the printed parts. As FRC is a combination of polymer matrix material and continuous or short reinforcing fibres, this review will thoroughly discuss both thermoplastic polymers and FRCs printed via FDM technology, including the effect of printing parameters such as layer thickness, infill pattern, raster angle and fibre orientation. The most common defects on printed parts, in particular, the void formation, surface roughness and poor bonding between fibre and matrix, are explored. An inclusive discussion on the effectiveness of chemical, laser, heat and ultrasound treatments to minimize these drawbacks is provided by this review.

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Section: Fibre-reinforced Composite Printingmentioning

confidence: 99%

FDM-Based 3D Printing of Polymer and Associated Composite: A Review on Mechanical Properties, Defects and Treatments

2020

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“…The most important conditions to produce elements via 3D printing processes were discussed on the work of Duty et al [10]. In the work of El Moumen et al [11], the effect of pores formation on the mechanical properties of 3D printed polymeric elements was investigated. This study was conducted using the homogenization technique based on the RVE (Representative Volume Element) notion.…”

Section: Introductionmentioning

confidence: 99%

Tensile and Compressive Behavior in the Experimental Tests for PLA Specimens Produced via Fused Deposition Modelling Technique

Brischetto

Torre

2020

J. Compos. Sci.

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In this paper, polymeric specimens are produced via the Fused Deposition Modelling (FDM) technique. Then, experimental tensile and compression tests are conducted to evaluate the main mechanical properties of elements made of PolyLacticAcid (PLA) material. A standardized characterization test method for FDM 3D printed polymers has not been developed yet. For this reason, the ASTM D695 (usually employed for polymers produced via classical methods) has been here employed for FDM 3D printed polymers after opportune modifications suggested by appropriate experimental checks. A statistical analysis is performed on the geometrical data of the specimens to evaluate the machine process employed for the 3D printing. A capability analysis is also conducted on the mechanical properties (obtained from the experimental tests) in order to calculate acceptable limits useful for possible structural analyses. The Young modulus, the proportional limit and the maximum strength here defined for PLA specimens allow to confirm the different behavior of FDM printed PLA material in tensile and compressive state. These differences and the calculated acceptable limits for the found mechanical properties must be considered when this technology will be employed for the design of small structural objects made of PLA, as in the present study, or ABS (Acrilonitrile Butadiene Stirene). From the statistical and capability analysis, the employed printing process appears as quite stable and replicable. These types of research together with other similar ones that will be conducted in the future will allow to use polymeric materials and the FDM technique to produce small structural elements and also to carry out the appropriate verifications.

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“… 42 The composite components, on the other hand, show a considerable variation in thermal properties and experience distinct thermal cycles during the subsequent processing. Hence, the appropriate choice of processing temperatures and cooling rates ensures quality prints, 43 and realizing such lightweight foams is crucial. The reinforcing matrix with hollow fillers results in the reduction of the matrix volume % leading to lightweight composite structures known as syntactic foams.…”

Section: Introductionmentioning

confidence: 99%

Three-Dimensional Printed Lightweight Composite Foams

et al. 2020

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The goal of this paper is to enable three-dimensional (3D) printed lightweight composite foams by blending hollow glass microballoons (GMBs) with high density polyethylene (HDPE). To that end, lightweight feedstock for printing syntactic foam composites is developed. The blend for this is prepared by varying the GMB content (20, 40, and 60 volume %) in HDPE for filament extrusion, which is subsequently used for 3D printing. The rheological properties and the melt flow index (MFI) of blends are investigated for identifying suitable printing parameters. It is observed that the storage and loss modulus, as well as complex viscosity, increase with increasing GMB content, whereas MFI decreases. Further, the coefficient of thermal expansion of HDPE and foam filaments decreases with increasing GMB content, thereby lowering the thermal stresses in prints, which promotes the reduction in warpage. The mechanical properties of filaments are determined by subjecting them to tensile tests, whereas 3D printed samples are tested under tensile and flexure tests. The tensile modulus of the filament increases with increasing GMB content (8–47%) as compared to HDPE and exhibit comparable filament strength. 3D printed foams show a higher specific tensile and flexural modulus as compared to neat HDPE, making them suitable candidate materials for weight-sensitive applications. HDPE having 60% by volume GMB exhibited the highest modulus and is 48.02% higher than the printed HDPE. Finally, the property map reveals a higher modulus and comparable strength against injection- and compression-molded foams. Printed foam registered 1.8 times higher modulus than the molded samples. Hence, 3D printed foams have the potential for replacing components processed through conventional manufacturing processes that have limitations on geometrically complex designs, lead time, and associated costs.

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Additive manufacturing of polymer composites: Processing and modeling approaches

Cited by 140 publications

References 148 publications

FDM-Based 3D Printing of Polymer and Associated Composite: A Review on Mechanical Properties, Defects and Treatments

FDM-Based 3D Printing of Polymer and Associated Composite: A Review on Mechanical Properties, Defects and Treatments

Tensile and Compressive Behavior in the Experimental Tests for PLA Specimens Produced via Fused Deposition Modelling Technique

Three-Dimensional Printed Lightweight Composite Foams

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