Design for additive manufacturing of composite materials and potential alloys: a review

Abstract

-As a first step of applying additive manufacturing (AM) technology, plastic prototypes have been produced using various AM Process such as Fusion Deposition Modeling (FDM), Stereolithography (SLA) and other processes. After more research and development, AM has become capable of producing complex net shaped in materials which can be used in applicable parts. These materials include metals, ceramics, and composites. Polymers and metals are considered as commercially available materials for AM processes; however, ceramics and composites are still considered under research and development. In this study, a literature review on design for AM of composite materials and potential alloys is discussed. It is investigated that polymer matrix, ceramic matrix, metal matrix, and fiber reinforced are most common composites through AM. Furthermore, Functionally Graded Materials (FGM) is considered as an effective application of AM because AM offers the ability to control the composition and optimize the properties of the built part. An example of FGM through using AM technology is the missile nose cone which includes an ultra-high temperature ceramic graded to a refractory metal from outside to inside and it used for sustaining extreme external temperatures. During this work, different applications of AM on different classifications of composite materials are shown through studying of industrial objective, the importance of application, processing, results and future challenges.

Additive Manufacturing of Polymer Matrix Composites

“…The first step of applying AM technology was historically producing plastic prototypes using various AM processes such as fused deposition modeling (FDM), stereolithography (SLA), and other processes. Producing complex net-shaped materials including metals, ceramics, and composites as functional parts later became available [2]. Today, polymers and metals are considered as commercially available materials for AM processes (see Figure 1).…”

“…As is the case with aircraft fuselage body where weight reduction while keeping the demanding mechanical properties is of uttermost importance, modern technology applications sometimes need materials with unusual combinations of properties which cannot be solely provided by metals, polymers, or ceramics. In this case, composite materials combining two or more materials allow us to have the preferred properties in one material [2].…”

Modelling of additive manufacturing processes: a review and classification

“…Additive manufacturing (AM) namely the process of joining materials for the production of objects, made of 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies [1] are applicable to a wide range of materials, including metals, composites [2] and even biomedical products [3]. AM [4] differs from rapid prototyping in the fact that AM specifically aims at the manufacturing of end user parts, rather than just prototypes [5].…”

How to Formulate for Structure and Texture via Medium of Additive Manufacturing-A Review

“…To differentiate themselves, various manufacturers often use different acronyms for describing the same process, and, therefore, similar techniques might have different names [43]. These have all been previously compared and reviewed comprehensively [17,[44][45][46], and many of these techniques have been individually reviewed in high detail including powder-based electron beam additive manufacturing (EBAM) technology [47], and the Fused Filament Fabrication (FFF) process, also termed, Fused Deposition Modelling (FDM) [48,49].…”