Hybrid Printing Method of Polymer and Continuous Fiber-Reinforced Thermoplastic Composites (CFRTPCs) for Pipes through Double-Nozzle Five-Axis Printer

Abstract

The most widely used 3D process, fused deposition modeling (FDM), has insufficient interlayer adhesion due to its layer-by-layer forming method. A support material is also essential for the hollow parts and cantilevers. Moreover, the polymer materials used have limited mechanical properties. These issues have restricted the application of FDM in high-performance fields. Continuous fiber-reinforced thermoplastic composites (CFRTPCs) have high mechanical properties and have recently become the focus of research in the field of 3D printing. This paper, using pipe parts as an example, proposes a hybrid of pure polymer (pure PLA used) and CFRTPC (flax fiber pre-impregnated filament) material to develop a printing method based on the outstanding mechanical properties of CFRTPC material. After studying the printing path planning algorithm, the CFRTPC filament is laid along the axial and radial directions on the surface of the polymer base to improve the printed parts’ properties. The method feasibility and algorithm accuracy are verified through the development of five-axis printing equipment with a double nozzle. Through the printed sample’s tensile, compression and bending tests, the results show that the tensile, compressive and bending properties of PLA pipe can be significantly enhanced by laying CFRTPC filament along the axial and radial directions of the pipe. To summarize, the introduction of CFRTPCs greatly improved the mechanical properties of the printed parts, and the implementation of our method provides an effective way to solve the defects of the FDM process.

Developing Eco-Friendly 3D-Printing Composite Filament: Utilizing Palm Midrib to Reinforce High-Density Polyethylene Matrix in Design Applications

“…This method emphasis the benefit of palm midrib in enhancing the characteristics and printability of HDPE composites. Comparison with other reinforcements: Comparing CFRTPCs and nanocellulose-based filaments with other reinforcements has shown the advantages of both fiber reinforcement and natural fillers [ 41 , 42 ]. However, HDPE/DPFNP composites offer a new material choice that combines the benefits of bio-based reinforcement with the well-known properties of HDPE.…”

Various FDM Mechanisms Used in the Fabrication of Continuous-Fiber Reinforced Composites: A Review

“…The former, thermoplastic, also known as thermosoft plastic, is a pliable plastic polymer that melts quickly at elevated temperatures and solidifies during the cooling process. The most widely used thermoplastics are PLA [ 53 , 54 ], ABS [ 37 ], polycarbonate (PC) [ 55 , 56 ], polypropylene (PP) [ 57 ], polyamide (PA) [ 58 , 59 ] (e.g., Nylon [ 60 , 61 , 62 ], polystyrene (PS), polyphenyl sulfone (PPSU), polyetheretherketone (PEEK) [ 63 ], polyaryletherketone (PAEK), and polyetherimide (PEI). Thermosets, conversely, are obtained by the irreversible hardening (curing) process of a soft solid or viscous liquid prepolymer (resin) [ 64 ].…”

Additive Manufacturing of Continuous Fiber-Reinforced Polymer Composites via Fused Deposition Modelling: A Comprehensive Review

“…When the resin-coated fiber is sent through the nozzle and onto the printing platform, it adheres to the layer that came before it and solidifies [90,91]. In the case of dual extrusion, the thermoplastic resin and the reinforcements are extruded separately onto the printing plate using two nozzles in the dual extrusion process [92]. Since the fiber in CFRP is always oriented in the same direction as the printing, it is possible to modify its orientation.…”