Effect of processing parameters on properties of printed and consolidated thermoplastic composites

Abstract

The process presented in the paper allows to produce bulk carbon fibre/thermoplastic composite parts with oriented continuous fibre to get specific mechanical loading constraints for structural parts. This fibre orientation allows to increase the mechanical strength of the composite product. This process consists of two steps: i) preforming and pre-consolidation necessary for the placement and orientation of the composite and ii) compression step. In this study, the first two steps are performed simultaneously by 3D printing. This study provides elements for optimizing certain process parameters and the associated results, particularly at different steps in the forming process. This paper also focuses on the movement of the material during shaping process. It links processing conditions and material characteristics, by determining the porosity and fibre ratio of composite part realized with different compression ratios. In addition, a repeatability study is conducted to identify the variability of the process and of the measurement method.