Batch production and fused filament fabrication of highly aligned discontinuous fibre thermoplastic filaments

Krajangsawasdi, Narongkorn; Longana, Marco L.; Hamerton, Ian; Woods, Benjamin K.S.; Ivanov, Dmitry

doi:10.1016/j.addma.2021.102359

Cited by 12 publications

(15 citation statements)

References 63 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Although the manufacturing methods for 3D printed FDM 3D printed discontinuous and aligned-fiber composites are different from the conventional make discontinuous and aligned-fiber composites, the motivations for reinforcing polymers with discontinuous and aligned-fiber are similar. In general discontinuous and aligned-fiber are added to polymers for three main reasons: (1) to improve mechanical, thermal, or electrical properties in the desired direction, (2) to reduce the cost and complexity of manufacturing compared to composites with continuous fibers, and (3) enabling design freedom or complex geometries [ 20 , 79 , 115 , 116 ]. FDM 3D printed discontinuous and aligned-fiber composites are mainly manufactured using composite filaments by commercial FDM 3D printers.…”

Section: Fiber Reinforced Polymer Composite (Frpc)mentioning

confidence: 99%

“…Researchers at the University of Bristol developed a method named High Performance Discontinues Fiber (HiPerDIF) to manufacture discontinuous and aligned-fiber composites [ 122 ] and investigated the performance of composites produced with this method [ 116 ]. Generally, the fibers were suspended in a liquid medium (water), and the orientation of fiber was controlled by the orientation head [ 122 ].…”

Section: Fiber Reinforced Polymer Composite (Frpc)mentioning

confidence: 99%

“…They managed to produce HiPerDiF-PLA filament and also identified the optimal printing parameters of their newly developed filament. They compared the mechanical properties of the HiPerDiF-PLA printed parts with PLA, PLA-short carbon fiber, PLA-continuous carbon fiber, and Markforged continuous carbon fiber [ 116 ], and they concluded that HiPerDiF-PLA outperformed other PLA composites in terms of mechanical performance.…”

Section: Fiber Reinforced Polymer Composite (Frpc)mentioning

confidence: 99%

See 2 more Smart Citations

3D-Printed Fiber-Reinforced Polymer Composites by Fused Deposition Modelling (FDM): Fiber Length and Fiber Implementation Techniques

2022

View full text Add to dashboard Cite

Fused Deposition Modelling (FDM) is an actively growing additive manufacturing (AM) technology due to its ability to produce complex shapes in a short time. AM, also known as 3-dimensional printing (3DP), creates the desired shape by adding material, preferably by layering contoured layers on top of each other. The need for low cost, design flexibility and automated manufacturing processes in industry has triggered the development of FDM. However, the mechanical properties of FDM printed parts are still weaker compared to conventionally manufactured products. Numerous studies and research have already been carried out to improve the mechanical properties of FDM printed parts. Reinforce polymer matrix with fiber is one of the possible solutions. Furthermore, reinforcement can enhance the thermal and electrical properties of FDM printed parts. Various types of fibers and manufacturing methods can be adopted to reinforce the polymer matrix for different desired outcomes. This review emphasizes the fiber types and fiber insertion techniques of FDM 3D printed fiber reinforcement polymer composites. A brief overview of fused deposition modelling, polymer sintering and voids formation during FDM printing is provided, followed by the basis of fiber reinforced polymer composites, type of fibers (synthetic fibers vs. natural fibers, continuous vs. discontinuous fiber) and the composites’ performance. In addition, three different manufacturing methods of fiber reinforced thermoplastics based on the timing and location of embedding the fibers, namely ‘embedding before the printing process (M1)’, ‘embedding in the nozzle (M2)’, and ‘embedding on the component (M3)’, are also briefly reviewed. The performance of the composites produced by three different methods were then discussed.

show abstract

Section: Fiber Reinforced Polymer Composite (Frpc)mentioning

confidence: 99%

Section: Fiber Reinforced Polymer Composite (Frpc)mentioning

confidence: 99%

Section: Fiber Reinforced Polymer Composite (Frpc)mentioning

confidence: 99%

See 1 more Smart Citation

3D-Printed Fiber-Reinforced Polymer Composites by Fused Deposition Modelling (FDM): Fiber Length and Fiber Implementation Techniques

2022

View full text Add to dashboard Cite

show abstract

“…In a previous study [ 18 ], carbon fibre preforms produced with the HiPerDiF were used as a reinforcement for PLA: a thin HiPerDiF-PLA tape was re-shaped by compression in a metallic mould under high temperature and finally pultruded to form a 1.2 mm diameter circular cross section suitable to be fed to a general 3D printer. The fine circular cross-section filament offers the possibility to manufacture more complex geometries with fewer defects than flat tape.…”

Section: Introductionmentioning

confidence: 99%

“…One of the limitations of the research presented in previous studies is that the filament-forming was performed manually [ 18 ], which is time and energy consuming and can only batch-produce a few centimetres of filament per hour. This is not sufficient for the printing of large parts.…”

Section: Introductionmentioning

confidence: 99%

Open Hole Tension of 3D Printed Aligned Discontinuous Composites

et al. 2022

View full text Add to dashboard Cite

This paper explores the use of Discontinuous Aligned Fibre Filament (DcAFF), a novel discontinuous fibre reinforced thermoplastic filament for 3D printing, to produce structural complex parts. Compared to conventional composite manufacturing, 3D printing has great potential in steering fibres around small structural features. In this current study, the initial thin carbon fibre (CF)-poly(L-lactic acid) (PLA) tape, produced with the High Performance Discontinuous Fibre (HiPerDiF) technology, is now reshaped into a circular cross-section filament, the DcAFF, using a bespoke machine designed to be scalable to high production rates rather than using a labour-intensive manual moulding method as in previous work. The filaments are then fed to a general-purpose 3D printer. Tensile and open-hole tensile tests were considered in this paper for mechanical and processability of DcAFF. The 3D printed specimens fabricated with the DcAFF show superior tensile properties compared to other PLA-based 3D printed composites, even those containing continuous fibres. Curvilinear open-hole tensile test samples were fabricated to explore the processability and performances of such material in complex shapes. The mechanical performance of the produced specimens was benchmarked against conventionally laid-up specimens with a cut hole. Although the steered specimens produced have lower strength than the fully consolidated samples, the raster generated by the printing path has turned the failure mechanism of the composite from brittle to ductile.

show abstract

Modelling on stress redistribution around broken fibers for fiber reinforced plastic with poor fiber distribution uniformity

Zhu

Jia

et al. 2022

Polymer Composites

View full text Add to dashboard Cite

In order to calculate stress redistribution after a fiber breaking for unidirectional fiber reinforced plastic (FRP) with practically poor fiber distribution uniformity, a new and efficient FE model is developed with high computation efficiency. Based on the proposed FE model, the stress concentration factor (SCF) of intact fibers around a broken fiber is investigated for unidirectional FRP. It is observed that the SCF depends heavily on the local fiber volume ratio (FVR), and a modified analytical SCF model is proposed which takes into account the variation of local FVR. It is proved that the modified analytical SCF model can provide SCF values with much better accuracy for FRP with poor fiber distribution uniformity. The modified analytical SCF model would be very useful for accurate prediction of progressive fiber breaking in FRP.

show abstract

Batch production and fused filament fabrication of highly aligned discontinuous fibre thermoplastic filaments

Cited by 12 publications

References 63 publications

3D-Printed Fiber-Reinforced Polymer Composites by Fused Deposition Modelling (FDM): Fiber Length and Fiber Implementation Techniques

3D-Printed Fiber-Reinforced Polymer Composites by Fused Deposition Modelling (FDM): Fiber Length and Fiber Implementation Techniques

Open Hole Tension of 3D Printed Aligned Discontinuous Composites

Modelling on stress redistribution around broken fibers for fiber reinforced plastic with poor fiber distribution uniformity

Contact Info

Product

Resources

About