Fibre misalignment and breakage in 3D printing of continuous carbon fibre reinforced thermoplastic composites

Zhang, Haoqi; Chen, Jiayun; Yang, Dongmin

doi:10.1016/j.addma.2020.101775

Cited by 59 publications

(37 citation statements)

References 26 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…How to improve the robustness of the stress-oriented CCF toolpaths under large deformation will be explored in our future work. Moreover, as discussed in [40], the problems of fibre misalignment and breakage during fibre deposition will also reduce the effectiveness of CCF reinforcement. How to generate toolpaths that can prevent these manufacturing failure cases is also possible future work.…”

Section: Discussionmentioning

confidence: 99%

Field-Based Toolpath Generation for 3D Printing Continuous Fibre Reinforced Thermoplastic Composites

Chen¹,

Fang²,

Liao³

et al. 2021

Preprint

View full text Add to dashboard Cite

We present a field-based method of toolpath generation for 3D printing continuous fibre reinforced thermoplastic composites. Our method employs the strong anisotropic material property of continuous fibres by generating toolpaths along the directions of tensile stresses in the critical regions. Moreover, the density of toolpath distribution is controlled in an adaptive way proportionally to the values of stresses. Specifically, a vector field is generated from the stress tensors under given loads and processed to have better compatibility between neighboring vectors. An optimal scalar field is computed later by making its gradients approximate the vector field. After that, isocurves of the scalar field are extracted to generate the toolpaths for continuous fibre reinforcement, which are also integrated with the boundary conformal toolpaths in user selected regions. The performance of our method has been verified on a variety of models in different loading conditions. Experimental tests are conducted on specimens by 3D printing continuous carbon fibres (CCF) in a polylactic acid (PLA) matrix. Compared to reinforcement by load-independent toolpaths, the specimens fabricated by our method show up to 71.4% improvement on the mechanical strength in physical tests when using the same (or even slightly smaller) amount of continuous fibres.

show abstract

Section: Discussionmentioning

confidence: 99%

Field-Based Toolpath Generation for 3D Printing Continuous Fibre Reinforced Thermoplastic Composites

Chen¹,

Fang²,

Liao³

et al. 2021

Preprint

View full text Add to dashboard Cite

show abstract

“…The longer the distance used to measure the curvature, the greater the amplitude of the in-depth position; the interpolation of the curvature will be therefore less sensitive to the variability of the position. Zhang et al modelled via FEA 3D printed continuous carbon filament to observe the influence of the printing path on the stresses inside the filament as well as on the geometric features of the print [36]. Those authors highlighted that the reduction of the printing radius in corners creates many defects, such as twist of the filament, error path, fibre breakage, folding and misalignment of the filament itself.…”

Section: Validity Of the Fea Modelmentioning

confidence: 99%

Design of 3d and 4d Printed Continuous Fibre Composites Via an Evolutionary Algorithm and Voxel-Based Finite Elements: Application to Natural Fibre Hygromorphs

Kergariou

Kim²,

Perriman³

et al. 2022

SSRN Journal

View full text Add to dashboard Cite

“…Zhang et al [ 11 ] studied the misalignment of fibre that formed during fabrication process and breakage of fibre in polymer composites using reinforced continuous carbon fibre in 3D printing. It was noticed that with the increase in turning angle and curvature, lots of printing defects and aggravate occurred due to the excessive tensile force from the nozzle.…”

Section: Introductionmentioning

confidence: 99%

Elastic Modulus and Flatwise (Through-Thickness) Tensile Strength of Continuous Carbon Fibre Reinforced 3D Printed Polymer Composites

et al. 2022

View full text Add to dashboard Cite

Additively manufactured composite specimens exhibit anisotropic properties, meaning that the elastic response changes with respect to orientation. Both in-plane and out-of-plane mechanical properties are important for designing purpose. Recent studies have characterised the in-plane performance. In this study, however, through-thickness tensile strength of 3D polymer composites were determined by printing of continuous carbon fibre reinforced thermoplastic polyamide-based composite, manufactured using a Markforged Two 3D printer. This paper discusses sample fabrication and geometry, adhesive used, and testing procedure. Test standards used to determine out-of-plane properties are tedious as most of the premature failures occur between the specimens and the tabs. Two types of samples were printed according to ASTM flatwise tension standard and the results were compared to determine the geometry effect on the interlaminar strength. This test method consists of subjecting the printed sample to a uniaxial tensile force normal to the plane. With this method, the acceptable failure modes for tensile strength must be internal to the structure, not between the sample and the end tabs. Micro-computed tomography (µCT) was carried out to observe the porosity. Surface behaviour was studied using scanning electron microscopy (SEM) to see the voids and the distribution of the fibres in the samples. The results showed consistent values for tensile strength and elastic modulus for Araldite glue after initial trials (with some other adhesives) to determine a suitable choice of adhesive for bonding the samples with the tabs. Circular specimens have higher tensile strength and elastic modulus as compared to rectangular specimens.

show abstract

Fibre misalignment and breakage in 3D printing of continuous carbon fibre reinforced thermoplastic composites

Cited by 59 publications

References 26 publications

Field-Based Toolpath Generation for 3D Printing Continuous Fibre Reinforced Thermoplastic Composites

Field-Based Toolpath Generation for 3D Printing Continuous Fibre Reinforced Thermoplastic Composites

Design of 3d and 4d Printed Continuous Fibre Composites Via an Evolutionary Algorithm and Voxel-Based Finite Elements: Application to Natural Fibre Hygromorphs

Elastic Modulus and Flatwise (Through-Thickness) Tensile Strength of Continuous Carbon Fibre Reinforced 3D Printed Polymer Composites

Contact Info

Product

Resources

About