Design and Fabrication of an In Situ Short-Fiber Doser for Fused Filament Fabrication 3D Printer: A Novel Method to Manufacture Fiber–Polymer Composite

Ismail, Khairul Izwan; Ramarad, Suganti; Yap, Tze Chuen

doi:10.3390/inventions8010010

Cited by 6 publications

(7 citation statements)

References 30 publications

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“…In this work, the 3D printer consists of two extruders, where one extruder deposits the neat PLA, and the other extruder, known as a fiber doser, deposits the milled glass fiber [ 28 ]. To fabricate the GFPLA composites, a novel fiber doser was designed and fabricated to deposit the glass fiber powder during printing [ 28 ]. The deposition rate of the glass fiber doser can be adjusted by controlling the motor speed of the fiber doser.…”

Section: Methodsmentioning

confidence: 99%

“…The GFPLA composites were differentiated via the fiber doser motor speed. Glass fiber content in each composite was then identified using the TGA [ 28 ]. The glass fiber content for all samples is presented in Table 4 .…”

Section: Methodsmentioning

confidence: 99%

“…Theoretically, the deposition of reinforcement, such as glass fiber powder, between the deposited filaments will reduce the voids which exist between the deposited filaments and act as a bridge to improve the layer-to-layer bond between the deposited filaments. A new method of embedding fibers on molten-deposited thermoplastic filament during the printing process was proposed recently [ 28 ]. The present work aims to investigate the tensile properties of the in situ-manufactured GFPLA composites, manufactured using the newly proposed method and compared with the non-reinforced counterpart, the neat PLA.…”

Section: Introductionmentioning

confidence: 99%

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Tensile Properties of In Situ 3D Printed Glass Fiber-Reinforced PLA

Ismail,

Pang,

Ahmed

et al. 2023

Polymers

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A 3D printed composite via the fused filament fabrication (FFF) technique has potential to enhance the mechanical properties of FFF 3D printed parts. The most commonly employed techniques for 3D composite printing (method 1) utilized premixed composite filaments, where the fibers were integrated into thermoplastic materials prior to printing. In the second method (method 2), short fibers and thermoplastic were mixed together within the extruder of a 3D printer to form a composite part. However, no research has been conducted on method 3, which involves embedding short fibers into the printed object during the actual printing process. A novel approach concerning 3D printing in situ fiber-reinforced polymer (FRP) by embedding glass fibers between deposited layers during printing was proposed recently. An experimental investigation has been undertaken to evaluate the tensile behavior of the composites manufactured by the new manufacturing method. Neat polylactic acid (PLA) and three different glass fiber-reinforced polylactic acid (GFPLA) composites with 1.02%, 2.39%, and 4.98% glass fiber contents, respectively, were 3Dprinted. Tensile tests were conducted with five repetitions for each sample. The fracture surfaces of the samples were then observed under scanning electron microscopy (SEM). In addition, the porosities of the 3D printed samples were measured with a image processing software (ImageJ 1.53t). The result shows that the tensile strengths of GFPLA were higher than the neat PLA. The tensile strength of the composites increased from GFPLA-1 (with a 1.02% glass fiber content) to GFPLA-2.4 (with a 2.39% glass fiber content), but drastically dropped at GFPLA-5 (with a 4.98% glass fiber content). However, the tensile strength of GFPLA-5 is still higher than the neat PLA. The fracture surfaces of tensile samples were observed under scanning electron microscopy (SEM). The SEM images showed the average line width of the deposited material increased as glass fiber content increased, while layer height was maintained. The intralayer bond of the deposited filaments improved via the new fiber embedding method. Hence, the porosity area is reduced as glass fiber content increased.

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Section: Methodsmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Tensile Properties of In Situ 3D Printed Glass Fiber-Reinforced PLA

Ismail,

Pang,

Ahmed

et al. 2023

Polymers

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“…161 PLA Successful in situ fiber deposition. 153 PLA and PP Successful printing of landing gears for unmanned aerial vehicles. 131…”

Section: Absmentioning

confidence: 99%

“…101,126,150,161 The corresponding manufacturer also leads the provision of commercial 3D printing composite filaments among the reviewed studies, being the creator of the Onyx ® filament-composed of polyamide filled with microcarbon fibers. 21 Apart from the aforementioned preimpregnated feedstock and the use of separate nozzles, Ismail et al 153 proposed a mechanism to deposit short fibers in situ, during printing, and between the polymer layers, potentially improving interlayer adhesion.…”

Section: Extrusion Mechanisms In 3d Printersmentioning

confidence: 99%

Polymeric composites in extrusion‐based additive manufacturing: a systematic review

Rodrigues,

Pires,

Barbosa

et al. 2024

Polymer Composites

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Solid composites used in material extrusion additive manufacturing have experienced considerable expansion over the past 5 years, incorporating functional properties into 3D‐printed objects. This paper presents a systematic review that aims to: (I) analyze the current state of development in the field; (II) quantify and categorize the adopted polymeric matrices, reinforcing materials, feedstock shapes, characterization strategies, and extrusion mechanisms; and (III) identify the applications, limitations, and trends for future research. The PRISMA statement was followed and the databases Scopus, Web of Science, and PubMed were consulted. Among the 116 included studies, the use of customized filaments surpassed the commercially available ones, with particulate matter being the most common form of filler when melt‐mixed with the polymer. Polyamide is the most widely adopted matrix (30.3%), followed by PLA (22.0%) and ABS (17.4%). In terms of reinforcements, carbon fiber (32.4%), glass fiber (12.5%), and ceramics (12.5%) compose the podium as the most frequently used, with nanofillers receiving increasing attention. In the conducted analysis, no standardized protocols were identified that clearly encompassed the entire process from feedstock formulation to technical prototype fabrication. At last, recycling, exploration of biodegradable materials, and 4D printing were identified as the main opportunities for future research.Highlights Reinforced polymers enable the enhancement of properties for 3D‐printed parts. Composite feedstock is usually formulated and mixed before printing. 3D printers with filament‐ or screw‐based extrusion mechanisms have been used. Mechanical and morphological analyses are common in material characterization. No identified applications were employed in real‐world scenarios.

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Innovative polymer‐based composite materials in additive manufacturing: A review of methods, materials, and applications

Wang,

Ding,

et al. 2024

Polymer Composites

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This review paper delves into the manufacturing methods, material properties, and applications of polymer‐based composites in the field of advanced manufacturing, offering a detailed explanation of their production through various additive manufacturing (AM) techniques and their diverse applications across multiple industries. Polymer‐based composite materials have emerged as crucial elements in AM due to their enhanced properties and design versatility, enabling the creation of components with unprecedented performance characteristics. The paper comprehensively covers the major AM methods employed for composite materials, including fused filament fabrication, Digital Light Processing/Stereolithography, Direct Ink Writing, and Selective Laser Sintering. Each of these methods is explored in terms of its mechanism, suitability for different composite materials, and the resulting material properties. The review also provides an insightful analysis of how these AM techniques are revolutionizing industries such as soft robotics, mechanical, electrical, and biomedical fields. The paper concludes by discussing the current challenges in this domain and projecting future trends in the development and application of composite materials in advanced manufacturing. This review aims to offer a comprehensive resource for researchers and practitioners in the field, highlighting the transformative impact of polymer‐based composites in AM and their growing significance across various sectors.Highlights Comprehensive review and classification of novelties in printing method for polymer based composite material manufacturing. Introduces innovative techniques to create and enhance material properties of composites. Explores interdisciplinary applications in biomedical, electronics, and sensors, demonstrating material versatility. Provides a systematic correlation between manufacturing method, material properties, and applications of novel polymer‐based composites.

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Design and Fabrication of an In Situ Short-Fiber Doser for Fused Filament Fabrication 3D Printer: A Novel Method to Manufacture Fiber–Polymer Composite

Cited by 6 publications

References 30 publications

Tensile Properties of In Situ 3D Printed Glass Fiber-Reinforced PLA

Tensile Properties of In Situ 3D Printed Glass Fiber-Reinforced PLA

Polymeric composites in extrusion‐based additive manufacturing: a systematic review

Innovative polymer‐based composite materials in additive manufacturing: A review of methods, materials, and applications

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