scholarly journals Review of mechanical properties of and optimisation methods for continuous fibre-reinforced thermoplastic parts manufactured by fused deposition modelling

2021 ◽  
Author(s):  
Michael Handwerker ◽  
Jörg Wellnitz ◽  
Hormoz Marzbani
Keyword(s):  
Mechanical Performance ◽  
Fused Deposition Modelling ◽  
Reinforced Plastics ◽  
Fused Deposition ◽  
Continuous Fibre ◽  
Current State ◽  
Thermoplastic Matrix ◽  
Glass Fibre Reinforced ◽  
Optimisation Methods ◽  
Air Void

AbstractA new way of manufacturing continuous fibre-reinforced plastics is the embedding of fibres in the filament of a 3D printer. This method could be used in manufacturing composite materials with a thermoplastic matrix containing glass, Kevlar and carbon fibres. This paper provides an overview of research on the mechanical and physical properties of these parts as well as optimisation approaches of additively manufactured thermoplastics. Furthermore, applicable testing and analysis methods and their corresponding standards are included. Several studies, which represent the current state of the art, are reviewed in detail for the analysis of the mechanical performance of different fibre reinforcements. In addition, an overview of different optimisation approaches is given. The ultimate tensile strength of Kevlar and glass fibre-reinforced parts are similar to those of common Aluminium alloys whereas the carbon fibre reinforced parts outperform their aluminium counterparts. Major performance limitations include a poor adhesion between layers as well as a high air void ratio.

scholarly journals Current State and Challenges of Natural Fibre-Reinforced Polymer Composites as Feeder in FDM-Based 3D Printing

Polymers ◽  
2021 ◽  
Vol 13 (14) ◽  
pp. 2289
Author(s):  
Nishata Royan Rajendran Royan ◽  
Jie Sheng Leong ◽  
Wai Nam Chan ◽  
Jie Ren Tan ◽  
Zainon Sharmila Binti Shamsuddin
Keyword(s):  
Mechanical Properties ◽  
Natural Fibre ◽  
Critical Discussion ◽  
Fused Deposition Modelling ◽  
Preparation Methods ◽  
Fused Deposition ◽  
Current State ◽  
Future Challenges ◽  
Raster Angle ◽  
Fibre Reinforced Polymer

As one of the fastest-growing additive manufacturing (AM) technologies, fused deposition modelling (FDM) shows great potential in printing natural fibre-reinforced composites (NFRC). However, several challenges, such as low mechanical properties and difficulty in printing, need to be overcome. Therefore, the effort to improve the NFRC for use in AM has been accelerating in recent years. This review attempts to summarise the current approaches of using NFRC as a feeder for AM. The effects of fibre treatments, composite preparation methods and addition of compatibilizer agents were analysed and discussed. Additionally, current methods of producing feeders from NFRCs were reviewed and discussed. Mechanical property of printed part was also dependent on the printing parameters, and thus the effects of printing temperature, layer height, infill and raster angle were discussed, and the best parameters reported by other researchers were identified. Following that, an overview of the mechanical properties of these composites as reported by various researchers was provided. Next, the use of optimisation techniques for NFRCs was discussed and analysed. Lastly, the review provided a critical discussion on the overall topic, identified all research gaps present in the use of NFRC for AM processes, and to overcome future challenges.

scholarly journals Fused Deposition Modelling of Fibre Reinforced Polymer Composites: A Parametric Review

2021 ◽  
Vol 5 (1) ◽  
pp. 29
Author(s):  
Narongkorn Krajangsawasdi ◽  
Lourens G. Blok ◽  
Ian Hamerton ◽  
Marco L. Longana ◽  
Benjamin K. S. Woods ◽  
...  
Keyword(s):  
Process Parameters ◽  
Mechanical Performance ◽  
Fibre Length ◽  
Processing Parameters ◽  
Thermoplastic Composite ◽  
Fused Deposition Modelling ◽  
Layer By Layer ◽  
Fused Deposition ◽  
Fibre Reinforced Polymer ◽  
Printing Parameters

Fused deposition modelling (FDM) is a widely used additive layer manufacturing process that deposits thermoplastic material layer-by-layer to produce complex geometries within a short time. Increasingly, fibres are being used to reinforce thermoplastic filaments to improve mechanical performance. This paper reviews the available literature on fibre reinforced FDM to investigate how the mechanical, physical, and thermal properties of 3D-printed fibre reinforced thermoplastic composite materials are affected by printing parameters (e.g., printing speed, temperature, building principle, etc.) and constitutive materials properties, i.e., polymeric matrices, reinforcements, and additional materials. In particular, the reinforcement fibres are categorized in this review considering the different available types (e.g., carbon, glass, aramid, and natural), and obtainable architectures divided accordingly to the fibre length (nano, short, and continuous). The review attempts to distil the optimum processing parameters that could be deduced from across different studies by presenting graphically the relationship between process parameters and properties. This publication benefits the material developer who is investigating the process parameters to optimize the printing parameters of novel materials or looking for a good constituent combination to produce composite FDM filaments, thus helping to reduce material wastage and experimental time.

scholarly journals The Influence of Manufacturing Parameters on the Mechanical Behaviour of PLA and ABS Pieces Manufactured by FDM: A Comparative Analysis

Materials ◽  
2018 ◽  
Vol 11 (8) ◽  
pp. 1333 ◽  
Author(s):  
Adrián Rodríguez-Panes ◽  
Juan Claver ◽  
Ana Camacho
Keyword(s):  
Tensile Strength ◽  
Mechanical Behaviour ◽  
Mechanical Performance ◽  
Acrylonitrile Butadiene Styrene ◽  
Polymer Materials ◽  
Fused Deposition Modelling ◽  
Fused Deposition ◽  
Layer Orientation ◽  
Lower Variability

This paper presents a comparative study of the tensile mechanical behaviour of pieces produced using the Fused Deposition Modelling (FDM) additive manufacturing technique with respect to the two types of thermoplastic material most widely used in this technique: polylactide (PLA) and acrylonitrile butadiene styrene (ABS). The aim of this study is to compare the effect of layer height, infill density, and layer orientation on the mechanical performance of PLA and ABS test specimens. The variables under study here are tensile yield stress, tensile strength, nominal strain at break, and modulus of elasticity. The results obtained with ABS show a lower variability than those obtained with PLA. In general, the infill percentage is the manufacturing parameter of greatest influence on the results, although the effect is more noticeable in PLA than in ABS. The test specimens manufactured using PLA perform more rigidly and they are found to have greater tensile strength than ABS. The bond between layers in PLA turns out to be extremely strong and is, therefore, highly suitable for use in additive technologies. The methodology proposed is a reference of interest in studies involving the determination of mechanical properties of polymer materials manufactured using these technologies.

Use of polymer concrete for large-scale 3D printing

2021 ◽  
Vol 27 (3) ◽  
pp. 465-474
Author(s):  
Martin Krčma ◽  
David Škaroupka ◽  
Petr Vosynek ◽  
Tomáš Zikmund ◽  
Jozef Kaiser ◽  
...  
Keyword(s):  
3D Printing ◽  
Large Scale ◽  
Mechanical Performance ◽  
Construction Material ◽  
Polymer Concrete ◽  
Fused Deposition Modelling ◽  
Cast State ◽  
Content Type ◽  
Fused Deposition ◽  
3D Printed

Purpose This paper aims to focus on the evaluation of a polymer concrete as a three-dimensional (3D) printing material. An associated company has developed plastic concrete made from reused unrecyclable plastic waste. Its intended use is as a construction material. Design/methodology/approach The concrete mix, called PolyBet, composed of polypropylene and glass sand, is printed by the fused deposition modelling process. The process of material and parameter selection is described. The mechanical properties of the filled material were compared to its cast state. Samples were made from castings and two different orientations of 3D-printed parts. Three-point flex tests were carried out, and the area of the break was examined. Computed tomography of the samples was carried out. Findings The influence of the 3D printing process on the material was evaluated. The mechanical performance of the longitudinal samples was close to the cast state. There was a difference in the failure mode between the states, with cast parts exhibiting a tougher behaviour, with fractures propagating in a stair-like manner. The 3D-printed samples exhibited high degrees of porosity. Originality/value The results suggest that the novel material is a good fit for 3D printing, with little to no degradation caused by the process. Layer adhesion was shown to be excellent, with negligible effect on the finished part for the longitudinal orientation. That means, if large-scale testing of buildability is successful, the material is a good fit for additive manufacturing of building components and other large-scale structures.

Use of Composite Materials for FDM 3D Print Technology

2016 ◽  
Vol 862 ◽  
pp. 174-181 ◽  
Author(s):  
Jiří Šafka ◽  
Michal Ackermann ◽  
Jiří Bobek ◽  
Martin Seidl ◽  
Jiří Habr ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Composite Materials ◽  
Fused Deposition Modelling ◽  
Two Phase ◽  
3D Print ◽  
Fused Deposition ◽  
Thermoplastic Matrix ◽  
Constant Diameter ◽  
Phase Systems ◽  
Progressive Technology

This article deals with specific polymer composites modified for the Fused Deposition Modelling (FDM) which is a 3D print technology. These two phase systems involve thermoplastic matrix filled with natural fibres. The crucial demand of this progressive technology is put on the accuracy of the semi-product formed into the filament shape. To reach the smooth production of 3D prototypes the filament should have a constant diameter. In the article, individual steps of the polymer composite pelletization and following pre-processing and processing activities are described. Among these steps the extrusion of the filaments belongs and subsequent print test on “RepRap” device accompanied by optimization of building parameters. Tensile specimens were chosen for print with regard to maps mechanical properties of this newly developed material which was the final stage of this work. Tensile test curves were then compared with those graphs which can be found for the material produced by conventional technologies such as injection moulding.

scholarly journals A review of recently developed polymer composite materials for fused deposition modeling 3D printing

2021 ◽  
Author(s):  
Surendra Singh Dewada ◽  
Amit Telang
Keyword(s):  
Polymer Nanocomposites ◽  
Fused Deposition Modeling ◽  
Mechanical Performance ◽  
Electrical Performance ◽  
Fused Deposition ◽  
Current State ◽  
Nano Clay ◽  
Functional Part ◽  
Deposition Modeling ◽  
Traditional Manufacturing

Abstract Additive Manufacturing (AM) is a rapidly evolving technology due to its numerous advantages over traditional manufacturing processes. AM processable materials are limited and have poor mechanical performance, restraining the technology's potential for functional part manufacturing. Although FDM is the most popular and growing technique, the inferiority of the material limits its application to prototyping. Nanocomposite material improves the thermal, mechanical, and electrical performance of FDM objects. Mostly polymer nanocomposites are feasible to process and several researchers have reported enhanced performance with polymer nanocomposites. Carbon nanotubes, graphene nanoplatelets, nano clay, and carbon fiber are primary reinforcements to thermoplastics. The current state of the art relevant to advances in nanocomposites for the FDM process, as well as the influence of nanofillers on mechanical properties of the build object are reviewed in this paper.

scholarly journals Printability and Tensile Performance of 3D Printed Polyethylene Terephthalate Glycol Using Fused Deposition Modelling

Polymers ◽  
2019 ◽  
Vol 11 (7) ◽  
pp. 1220 ◽  
Author(s):  
Sofiane Guessasma ◽  
Sofiane Belhabib ◽  
Hedi Nouri
Keyword(s):  
Polyethylene Terephthalate ◽  
Mechanical Performance ◽  
Substantial Reduction ◽  
Fused Deposition Modelling ◽  
X Ray ◽  
Fused Deposition ◽  
Wide Range ◽  
Tensile Performance ◽  
3D Printed ◽  
Micro Tomography

Polyethylene terephthalate glycol (PETG) is a thermoplastic formed by polyethylene terephthalate (PET) and ethylene glycol and known for his high impact resistance and ductility. The printability of PETG for fused deposition modelling (FDM) is studied by monitoring the filament temperature using an infra-red camera. The microstructural arrangement of 3D printed PETG is analysed by means of X-ray micro-tomography and tensile performance is investigated in a wide range of printing temperatures from 210 °C to 255 °C. A finite element model is implemented based on 3D microstructure of the printed material to reveal the deformation mechanisms and the role of the microstructural defects on the mechanical performance. The results show that PETG can be printed within a limited range of printing temperatures. The results suggest a significant loss of the mechanical performance due to the FDM processing and particularly a substantial reduction of the elongation at break is observed. The loss of this property is explained by the inhomogeneous deformation of the PETG filament. X-ray micro-tomography results reveal a limited amount of process-induced porosity, which only extends through the sample thickness. The FE predictions point out the combination of local shearing and inhomogeneous stretching that are correlated to the filament arrangement within the plane of construction.

Parametric study on tensile and flexural properties of ULTEM 1010 specimens fabricated via FDM

2021 ◽  
Vol 27 (2) ◽  
pp. 429-451
Author(s):  
Chrysoula Pandelidi ◽  
Tobias Maconachie ◽  
Stuart Bateman ◽  
Ingomar Kelbassa ◽  
Sebastian Piegert ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
High Temperature ◽  
Process Parameters ◽  
Computer Aided Design ◽  
High Performance ◽  
Mechanical Performance ◽  
Fused Deposition Modelling ◽  
Controlled Cooling ◽  
Content Type ◽  
Fused Deposition

Purpose Fused deposition modelling (FDM) is increasingly being explored as a commercial fabrication method due to its ability to produce net or near-net shape parts directly from a computer-aided design model. Other benefits of technology compared to conventional manufacturing include lower cost for short runs, reduced product lead times and rapid product design. High-performance polymers such as polyetherimide, have the potential for FDM fabrication and their high-temperature capabilities provide the potential of expanding the applications of FDM parts in automotive and aerospace industries. However, their relatively high glass transition temperature (215 °C) causes challenges during manufacturing due to the requirement of high-temperature build chambers and controlled cooling rates. The purpose of this study is to investigate the mechanical properties of ULTEM 1010, an unfilled polyetherimide grade. Design/methodology/approach In this research, mechanical properties were evaluated through tensile and flexural tests. Analysis of variance was used to determine the significance of process parameters to the mechanical properties of the specimens, their main effects and interactions. The fractured surfaces were analysed by scanning electron microscopy and optical microscopy and porosity was assessed by X-ray microcomputed tomography. Findings A range of mean tensile and flexural strengths, 60–94 MPa and 62–151 MPa, respectively, were obtained highlighting the dependence of performance on process parameters and their interactions. The specimens were found to fracture in a brittle manner. The porosity of tensile samples was measured between 0.18% and 1.09% and that of flexural samples between 0.14% and 1.24% depending on the process parameters. The percentage porosity was found to not directly correlate with mechanical performance, rather the location of those pores in the sample. Originality/value This analysis quantifies the significance of the effect of each of the examined process parameters has on the mechanical performance of FDM-fabricated specimens. Further, it provides a better understanding of the effect process parameters and their interactions have on the mechanical properties and porosity of FDM-fabricated polyetherimide specimens. Additionally, the fracture surface of the tested specimens is qualitatively assessed.

Effect of carbon fibre on reinforcement of thermoplastics using FDM and RSM

2019 ◽  
pp. 089270571988689 ◽  
Author(s):  
Fausz Naeem Chaudhry ◽  
Shahid Ikramullah Butt ◽  
Aamir Mubashar ◽  
Ali Bin Naveed ◽  
Syed Hussain Imran ◽  
...  
Keyword(s):  
Carbon Fibre ◽  
Fused Deposition Modelling ◽  
Reinforced Composites ◽  
Fused Deposition ◽  
Continuous Fibre ◽  
Manufacturing Operations ◽  
Testing Parameter ◽  
Reinforced Thermoplastics ◽  
3D Printing Technique ◽  
Fibre Reinforced Composites

Continuous fibre-reinforced composites have significant industrial importance and usage. However, they are limited by design considerations and high-cost manufacturing operations. This article presents a way forward to utilize Fused Deposition Modelling – a 3D printing technique – to manufacture continuous carbon fibre-reinforced thermoplastics. Several parameters including number of reinforced layers, material impact and interlayer gap have been investigated and optimized using response surface method. Successful incorporation of modified novel nozzle design in a dual nozzle setup resulted in the realization of controlled manufacturing of continuously reinforced composites leading to reinforced yet smooth surface finished samples. Several samples were made, and mechanical testing, parameter optimization, strength calculations and fracture analysis were carried out. For polylactic acid (PLA), tensile strength of 112 MPa and flexural strength of 164 MPA were achieved – an almost 3 times increase from pure PLA printing. The approach presented in this article can forward continuous fibre-reinforced composites for industrial usage with its controlled fibre layup and programmable thread orientation features.

Sign in / Sign up

Export Citation Format

Share Document