Multi-Axis Multi-Material Fused Filament Fabrication with Continuous Fiber Reinforcement

Backer, Wout De; Bergs, Arturs P.; Tooren, Michael J. Van

doi:10.2514/6.2018-0091

Cited by 27 publications

(14 citation statements)

References 2 publications

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“…In this respect, different improvements are currently being implemented in the process for the reduction of defects and limitations: material preheating systems [51], layer post-compacting systems [52], multi-axis 3D-printing [53] and simultaneous extrusion of different filaments [54].…”

Section: Discussionmentioning

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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Section: Discussionmentioning

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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show abstract

“…Dai et al [10] proposed a method to deposit material on curved layers using a multi-axis printing system based on a robot arm, significantly reducing the need for support structures and avoid collisions. In order to enhance the strength of the printed parts, De et al [11] used a robotic printing platform to print continuous carbon fiber on multiple axes. However, the platform had a sophisticated end-effector to achieve multi-material extrusion.…”

Section: Related Work 21 Multi-dof 3d Printingmentioning

confidence: 99%

3D Printing of Objects with Continuous Spatial Paths by a Multi-Axis Robotic FFF Platform

2021

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Conventional Fused Filament Fabrication (FFF) equipment can only deposit materials in a single direction, limiting the strength of printed products. Robotic 3D printing provides more degrees of freedom (DOF) to control the material deposition and has become a trend in additive manufacturing. However, there is little discussion on the strength effect of multi-DOF printing. This paper presents an efficient process framework for multi-axis 3D printing based on the robot to improve the strength. A multi-DOF continuous toolpath planning method is designed to promote the printed part’s strength and surface quality. We generate curve layers along the model surfaces and fill Fermat spiral in the layers. The method makes it possible to take full advantage of the multi-axis robot arm to achieve smooth printing on surfaces with high curvature and avoid the staircase effect and collision in the process. To further improve print quality, a control strategy is provided to synchronize the material extrusion and robot arm movement. Experiments show that the tensile strength increases by 22–167% compared with the conventional flat slicing method for curved-surface parts. The surface quality is improved by eliminating the staircase effect. The continuous toolpath planning also supports continuous fiber-reinforced printing without a cutting device. Finally, we compared with other multi-DOF printing, the application scenarios, and limitations are given.

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“…Industrial robots have a high degree of freedom, enabling the construction of complex objects without supporting structures [5]. For example, De Backer et al [6] studied the multi-material fused filament fabrication with continuous fiber reinforcements by using an industrial robot. Generally, the deformation of printed continuous fiber reinforced polymer composite is induced by temperature variation and external forces.…”

Section: Introductionmentioning

confidence: 99%

LiDAR Based Multi-Robot Cooperation for the 3D Printing of Continuous Carbon Fiber Reinforced Composite Structures

Li¹,

Link²,

Ma³

et al. 2021

Advances in Transdisciplinary Engineering

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3D printing of lightweight continuous carbon fiber reinforced plastics (CCFRP) in three dimensions changes the traditional composite manufacturing processes. The continuous carbon fibers reinforced plastic filament can be printed along the load transmission path and significantly improve the strength of composite structures. Compared to the three-axis computer numerical controlled (CNC) machine based printing process, industrial robots provide the possibility to manufacture complex, spatial and large-scale composite structures. Here, the concept to use multi-robot to print complex spatial CCFRP components simultaneously has been presented. More than one 6 degrees of freedom industrial robots can cooperate with each other and solve the contradiction between structural complexity and printing reachability. During the printing process, the deformation of composite structures may happen, especially for the self-supporting components. Thus, in this paper, a Light Detection and Ranging (LiDAR) method is introduced to detect the deformation of printed composite structure and the movements of two UR robots. To obtain the point clouds of the printed structure, a LiDAR camera D435i has been installed on one robot. A new approach by combining coordinate transformation and iterative-closest-point (ICP) algorithm has been developed to merge the point clouds collected from different shooting angles of the camera.

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Multi-Axis Multi-Material Fused Filament Fabrication with Continuous Fiber Reinforcement

Cited by 27 publications

References 2 publications

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

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

3D Printing of Objects with Continuous Spatial Paths by a Multi-Axis Robotic FFF Platform

LiDAR Based Multi-Robot Cooperation for the 3D Printing of Continuous Carbon Fiber Reinforced Composite Structures

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