Development of 3D-printed basalt fiber reinforced thermoplastic honeycombs with enhanced compressive mechanical properties

Sang, Lin; Han, Shuangfeng; Peng, Xingshuang; Jian, Xigao; Wang, Jinyan

doi:10.1016/j.compositesa.2019.105518

Cited by 76 publications

(27 citation statements)

References 37 publications

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“…Some examples of the applications of fibre-reinforced polymer composites include high-temperature inlet guide vanes (IGV) for aerospace applications, printed using polyetherimides- Ultem 1000 mixed with 10% chopped carbon fibre [ 19 , 37 ]. Sang et al [ 38 ] developed promising PLA-PCL/basalt fibre composite filaments, to be used as FFF feedstock for manufacturing honeycomb structures that exhibit elastic deformations with superior energy absorption under compressive loading, and which provide valuable means to obtain an excellent compressive mechanical performance in honeycomb structures ( Figure 4 ).…”

Section: 3d Printing Of Short Fibre-reinforced Compositementioning

confidence: 99%

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3D Printing of Fibre-Reinforced Thermoplastic Composites Using Fused Filament Fabrication—A Review

2020

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Three-dimensional (3D) printing has been successfully applied for the fabrication of polymer components ranging from prototypes to final products. An issue, however, is that the resulting 3D printed parts exhibit inferior mechanical performance to parts fabricated using conventional polymer processing technologies, such as compression moulding. The addition of fibres and other materials into the polymer matrix to form a composite can yield a significant enhancement in the structural strength of printed polymer parts. This review focuses on the enhanced mechanical performance obtained through the printing of fibre-reinforced polymer composites, using the fused filament fabrication (FFF) 3D printing technique. The uses of both short and continuous fibre-reinforced polymer composites are reviewed. Finally, examples of some applications of FFF printed polymer composites using robotic processes are highlighted.

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Section: 3d Printing Of Short Fibre-reinforced Compositementioning

confidence: 99%

“… 3D printed circular honeycombs of PLA-PCL/KBF with varying ratios [ 38 ]. The PLA-PCL/KBF composite consists of polylactic acid (PLA) as the stiff matrix, polycaprolactone (PCL) as an elastomer phase and silane-treated basalt fibres (KBF) as the reinforcing filler.…”

Section: Figurementioning

confidence: 99%

3D Printing of Fibre-Reinforced Thermoplastic Composites Using Fused Filament Fabrication—A Review

2020

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“…In this range of viscosity, the polymer melt was suitable to flow, wet and spread, while supporting itself [ 16 ]. In another approach, the identification of a crossover point using dynamic shear rheology was indicative of melt elasticity and was applied to assess the suitability of a material for ME processing [ 17 , 18 ].…”

Section: Introductionmentioning

confidence: 99%

Rheology and 3D Printability of Percolated Graphene–Polyamide-6 Composites

et al. 2020

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Graphene–polyamide-6 (PA6) composites with up to 17.0%·w/w graphene content were prepared via melt mixing. Oscillatory rheometry revealed that the dynamic viscoelastic properties of PA6 decreased with the addition of 0.1%·w/w graphene but increased when the graphene content was increased to 6.0%·w/w and higher. Further analysis indicated that the rheological percolation threshold was between 6.0 and 10.0%·w/w graphene. The Carreau–Yasuda model was used to describe the complex viscosity of the materials. Capillary rheometry was applied to assess the steady shear rheology of neat PA6 and the 17.0%·w/w graphene–PA6 composite. High material viscosity at low shear rates coupled with intense shear-thinning in the composite highlighted the importance of selecting the appropriate rheological characterisation methods, shear rates and rheological models when assessing the 3D printability of percolated graphene–polymer composites for material extrusion (ME). A method to predict the printability of an ME filament feedstock, based on fundamental equations describing material flow through the printer nozzle, in the form of a printing envelope, was developed and verified experimentally. It was found that designing filaments with steady shear viscosities of approximately 15% of the maximum printable viscosity for the desired printing conditions will be advantageous for easy ME processing.

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“…Several studies have been conducted on the use of basalt fiber as a reinforcing material in a thermoplastic composite material [31][32][33][34][35][36]. Only three studies have focused on 3D printing basalt fiber composite materials and all have used PLA as the matrix material [37][38][39]. While all of these studies have shown success in using basalt fibers as a reinforcing material for their specific applications, none have focused on use for in-space manufacturing and the unique design thought process needed for this application.…”

Section: Introductionmentioning

confidence: 99%

Development and Mechanical Properties of Basalt Fiber-Reinforced Acrylonitrile Butadiene Styrene for In-Space Manufacturing Applications

et al. 2019

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A new basalt fiber reinforced acrylonitrile butadiene styrene (ABS) filament has been developed for fused filament fabrication (FFF, 3D printing) to be used in Mars habitat construction. Building habitats on Mars will be expensive, especially if all material must be shipped from earth. However, if some materials can be used from Mars, costs will dramatically decrease. Basalt is easily mined from the surface of Mars. This study details the production process of the material, experimental results from mechanical testing, and preliminary X-ray shielding characteristics. The addition of chopped 3 mm basalt fibers to standard FFF material, ABS, increased strength and stiffness of the composite material. By adding 25% (by weight) basalt fiber to ABS, tensile strength improved nearly 40% by increasing from 36.55 MPa to 50.58 MPa, while Modulus of Elasticity increased about 120% from 2.15 GPa to 4.79 GPa. Flexural strength increased by about 20% from 56.94 MPa to 68.51 MPa, while Flexural Modulus increased by about 70% from 1.81 GPa to 3.05 GPa. While compression results did not see much strength improvements, the addition of fibers also did not decrease compressive strength. This is important when considering that basalt fibers provide radiation shielding and the cost of adding basalt fibers to construction materials on Mars will be negligible compared to the cost of shipping other materials from earth. In preliminary digital radiography testing, it was shown that 77% of X-rays were shielded with 25% basalt fiber added (as compared to neat ABS). In small-scale 3D printing applications, the 25% fiber ratio seems to be the highest ratio that provides reliable FFF printing.

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Development of 3D-printed basalt fiber reinforced thermoplastic honeycombs with enhanced compressive mechanical properties

Cited by 76 publications

References 37 publications

3D Printing of Fibre-Reinforced Thermoplastic Composites Using Fused Filament Fabrication—A Review

3D Printing of Fibre-Reinforced Thermoplastic Composites Using Fused Filament Fabrication—A Review

Rheology and 3D Printability of Percolated Graphene–Polyamide-6 Composites

Development and Mechanical Properties of Basalt Fiber-Reinforced Acrylonitrile Butadiene Styrene for In-Space Manufacturing Applications

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