Exploration of the design freedom of 3D printed continuous fibre-reinforced polymers in open-hole tensile strength tests

Pyl, Lincy; Kalteremidou, Kalliopi-Artemi; Hemelrijck, Danny Van

doi:10.1016/j.compscitech.2018.12.021

Cited by 49 publications

(17 citation statements)

References 37 publications

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“…On the other hand, all this information is very important for designing and characterizing a composite part as well as predicting the mechanical properties. A number of research works have been published that used the Mark Two printer, and few of them examined only a few of these issues that were related to their respective work [10][11][12][13][14][15][16][17].…”

Section: Introductionmentioning

confidence: 99%

The Road to Improved Fiber-Reinforced 3D Printing Technology

2020

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Three-dimensional printing (3DP) is at the forefront of the disruptive innovations adding a new dimension in the material fabrication process with numerous design flexibilities. Especially, the ability to reinforce the plastic matrix with nanofiber, microfiber, chopped fiber and continuous fiber has put the technology beyond imagination in terms of multidimensional applications. In this technical paper, fiber and polymer filaments used by the commercial 3D printers to develop fiber-reinforced composites are characterized to discover the unknown manufacturing specifications such as fiber–polymer distribution and fiber volume fraction that have direct practical implications in determining and tuning composites’ properties and their applications. Additionally, the capabilities and limitations of 3D printing software to process materials and control print parameters in relation to print quality, structural integrity and properties of printed composites are discussed. The work in this paper aims to present constructive evaluation and criticism of the current technology along with its pros and cons in order to guide prospective users and 3D printing equipment manufacturers on improvements, as well as identify the potential avenues of development of the next generation 3D printed fiber-reinforced composites.

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Section: Introductionmentioning

confidence: 99%

The Road to Improved Fiber-Reinforced 3D Printing Technology

2020

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“…Advanced numerical models based on advanced failure criteria and continuum damage mechanisms were developed for the design of these laminates, and were successfully tested on components manufactured by Automated Fibre Placement (AFP) [9][10][11]. Although some preliminary studies have been carried out [12][13][14], the applicability of 3D-printing technology for the manufacture of non-conventional laminates is still to be developed. To design and manufacture these types of structures with 3D-printing, the printing process limitations and the mechanical behaviour of the printed materials must be known in depth.…”

Section: Introductionmentioning

confidence: 99%

Ply and interlaminar behaviours of 3D printed continuous carbon fibre-reinforced thermoplastic laminates; effects of processing conditions and microstructure

Iragi

Pascual-González

Esnaola

et al. 2019

Additive Manufacturing

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Taking advantage of an extended design and manufacturing space for composites, the technology of Fused Filament Fabrication (FFF) of continuous fibre-reinforced thermoplastics shows great potential for the production of the next generation of lightweight structural parts. This novel process is very much under development, and knowledge of the mechanical behaviour of the resulting 3D-printed materials is still limited. In this work, the intra-and inter-laminar behaviours of carbon fibre/polyamide printed laminates were extensively characterised to determine ply elastic and strength properties, as well as interface strength and fracture characteristics. Moreover, the effects of eventual production defects on these properties were analysed, putting in evidence some of the present shortcomings of the FFF process. Such defects include non-homogeneous fibre distribution, large amounts of intra-and interlaminar voids, and weak interlayer bonding, which are likely to be due to insufficient thermo-mechanical consolidation of the material during the FFF process, and have significant influence on the matrix-dominated mechanical properties. As a result, the transverse and interlaminar properties were found to be lower than those obtained through Hot Compression Moulding of an equivalent material. Besides highlighting possible process improvements, the mechanical characterisation carried out in this work promises a significant

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“…Pyl et al also used the Mark Two to fabricate 200 mm Â 30 mm Â 1.25-1.625 mm rectangular and 165 mm Â 36 mm Â 2.25 mm dumbbell PA matrix composite material specimens, respectively, with aligned continuous carbon fibers. [81] They found that drilling holes, with continuous filler material placed concentrically around the drilling location, reduces stress concentrations compared to printing holes. In a different study, Naranjo-Lozada et al used the Mark Two to print three types of 57 mm Â 13 mm Â 3.2 mm tensile test specimens: PA (1.75 mm filament diameter), Onyx (1.75 mm filament diameter), and PA with continuous carbon fiber (0.35 mm tow diameter) filaments with 4-54 vol% filler material.…”

Section: Fused Filament Fabricationmentioning

confidence: 99%

Additive Manufacturing of Polymer Matrix Composite Materials with Aligned or Organized Filler Material: A Review

Niendorf

Raeymaekers

2021

Adv Eng Mater

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The ability to fabricate polymer matrix composite materials with continuous or discontinuous filler material, oriented in a user-specified direction, enables implementing designer material properties, such as anisotropic mechanical, thermal, and electrical properties. Conventional fabrication methods rely on a mold, which limits specimen geometry and is difficult to implement. In contrast, additive manufacturing, including fused filament fabrication or fused deposition modeling, direct ink writing, or stereolithography, combined with a method to align filler material such as a mechanical force or an electric, magnetic, shear force, or ultrasound wave field, enables 3D printing polymer matrix composite material specimens with complex geometry and aligned filler material, without the need for a mold. Herein, we review the combinations of fabrication and filler material alignment methods used to fabricate polymer matrix composite materials, in terms of operating and design parameters including size, resolution, print speed, filler material alignment time, polymer matrix and filler material requirements, and filler manipulation requirements. The operating envelope of each fabrication method is described and their advantages, disadvantages, and limitations are discussed. Finally, different combinations of 3D printing and filler material alignment methods in the context of important engineering applications, such as structural materials, flexible electronics, and shape-changing materials, are illustrated.

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Exploration of the design freedom of 3D printed continuous fibre-reinforced polymers in open-hole tensile strength tests

Cited by 49 publications

References 37 publications

The Road to Improved Fiber-Reinforced 3D Printing Technology

The Road to Improved Fiber-Reinforced 3D Printing Technology

Ply and interlaminar behaviours of 3D printed continuous carbon fibre-reinforced thermoplastic laminates; effects of processing conditions and microstructure

Additive Manufacturing of Polymer Matrix Composite Materials with Aligned or Organized Filler Material: A Review

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