scholarly journals FE modeling of continuous fiber reinforced thermoplastic composite structures produced by additive manufacturing

2020 ◽  
Vol 776 ◽  
pp. 012080
Author(s):  
J Majko ◽  
M Sága ◽  
M Vaško ◽  
M Handrik ◽  
Z Ságová
Keyword(s):  
Additive Manufacturing ◽  
Composite Structures ◽  
Thermoplastic Composite ◽  
Fe Modeling ◽  
Fiber Reinforced ◽  
Continuous Fiber

Feasibility and Characterization of Large-Scale Additive Manufacturing With Long Fiber Reinforced Composites

2020 ◽  
Author(s):  
Aditya R. Thakur ◽  
Ming C. Leu ◽  
Xiangyang Dong
Keyword(s):  
Additive Manufacturing ◽  
Carbon Fiber ◽  
Carbon Fibers ◽  
Large Scale ◽  
Flexural Modulus ◽  
High Deposition Rate ◽  
Reinforced Composites ◽  
Fiber Reinforced ◽  
Continuous Fiber ◽  
Long Carbon Fibers

Abstract A new additive manufacturing (AM) approach to fabricate long fiber reinforced composites (LFRC) was proposed in this study. A high deposition rate was achieved by the implementation of a single-screw extruder, which directly used thermoplastic pellets and continuous fiber tows as feedstock materials. Thus, the proposed method was also used as a large-scale additive manufacturing (LSAM) method for printing large-volume components. Using polylactic acid (PLA) pellets and continuous carbon fiber tows, the feasibility of the proposed AM method was investigated through printing LFRC samples and further demonstrated by fabricating large-volume components with complex geometries. The printed LFRC samples were compared with pure thermoplastic and continuous fiber reinforced composite (CFRC) counterparts via mechanical tests and microstructural analyses. With comparable flexural modulus, the flexural strength of the LFRC samples was slightly lower than that of the CFRC samples. An average improvement of 28% in flexural strength and 50% in flexural modulus were achieved compared to those of pure PLA parts, respectively. Discontinuous long carbon fibers, with an average fiber length of 20.1 mm, were successfully incorporated into the printed LFRC samples. The carbon fiber orientation, distribution of carbon fiber length, and dispersion of carbon fiber as well as porosity were further studied. The carbon fibers were highly oriented along the printing direction with a relatively uniformly distributed fiber reinforcement across the LFRC cross section. With high deposition rate (up to 0.8 kg/hr) and low material costs (< $10/kg), this study demonstrated the potentials of the proposed printing method in LSAM of high strength polymer composites reinforced with long carbon fibers.

Recent Patents in Additive Manufacturing of Continuous Fiber Reinforced Composites

2019 ◽  
Vol 12 (1) ◽  
pp. 25-36 ◽  
Author(s):  
Chao Hu ◽  
Zeyu Sun ◽  
Yi Xiao ◽  
Qinghua Qin
Keyword(s):  
Additive Manufacturing ◽  
Raw Materials ◽  
Fiber Reinforced Composites ◽  
Reinforced Composites ◽  
Fiber Reinforced ◽  
Continuous Fiber ◽  
Manufacturing Method ◽  
Carbon Fiber Reinforced Composites ◽  
Bending Stresses ◽  
Continuous Carbon Fiber

Background: Additive Manufacturing (AM) enables the accurate fabrication of designed parts in a short time without the need for specific molds and tools. Although polymers are the most widely used raw materials for AM, the products printed by them are inherently weak, unable to sustain large tension or bending stresses. A need for the manufacturing of fiber reinforced composites, especially continuous fiber as reinforcement, has attracted great attention in recent years. Objective: Identifying the progress of the AM of continuous carbon fiber reinforced composites over time and therefore establishing a foundation on which current research can be based. Methods: Elaborating the most related patents regarding the AM techniques for fabricating continuous fiber reinforced composites in the top three institutions, including Markforged company, Xi’an Jiaotong University and President and Fellows of Harvard College. Results: The recent patents in AM of continuous fiber reinforced composites are classified into two aspects: patents related to novel technique methods and patents related to novel structures. The current issues and future development of AM-based composites are given. Conclusion: New structures and techniques have been introduced into conventional 3D printers to enable the printing of continuous fiber reinforced composites. However, until now, Markforged is the only company commercializing the fabrication of this kind of composites based on AM technique. Numerous challenges and issues need to be solved so that AM of continuous fiber reinforced composites can be a new manufacturing method.

A Modeling Method of Continuous Fiber Paths for Additive Manufacturing (3D Printing) of Variable Stiffness Composite Structures

2020 ◽  
Vol 27 (3) ◽  
pp. 185-208
Author(s):  
Andrei V. Malakhov ◽  
Alexander N. Polilov ◽  
Junkang Zhang ◽  
Zhanghao Hou ◽  
Xiaoyong Tian
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Composite Structures ◽  
Variable Stiffness ◽  
Modeling Method ◽  
Continuous Fiber

Experimental Investigations on Integrated Conductor Paths in Fiber-Reinforced Thermoplastic Composite Structures

2017 ◽  
Vol 742 ◽  
pp. 793-799
Author(s):  
Tony Weber ◽  
Anja Winkler ◽  
Maik Gude
Keyword(s):  
Composite Structures ◽  
Construction Material ◽  
Functional Integration ◽  
Thermoplastic Composite ◽  
Experimental Investigations ◽  
Film Material ◽  
Fiber Reinforced ◽  
Forming Process ◽  
Sensors And Actuators ◽  
Definition Of

By the benefit of functional integration the advantages of fiber reinforced plastics (FRP) as construction material can be increased due to the possibilities of integrating sensors and actuators. In Regard to the layer-by-layer definition of the wall thickness, this class of material offers a high potential for the integration of additional smart elements within the stacking and forming process. In addition to the actual integration methods of sensors or actuators, the electrical signal transmission and contacting is of great importance for smart structures. Various approaches can be followed. On the one hand, the conductor path can be defined by means of a wire and, on the other hand, the definition of conductor paths can be accomplished by functionalized films (by means of printing technology). Within this paper, experimental investigations are intended to demonstrate the suitability of screen-printed conductor paths for the press-technical transformation of FRP structures. In addition to the variation of the screen printing material and the film material, for a material-homogeneous integration, an evaluation of a corresponding selection of materials takes place with respect to the stresses derived from the deformation-technical boundary conditions.

Laser assisted additive manufacturing of continuous fiber reinforced thermoplastic composites

2017 ◽  
Vol 131 ◽  
pp. 186-195 ◽  
Author(s):  
Pedram Parandoush ◽  
Levi Tucker ◽  
Chi Zhou ◽  
Dong Lin
Keyword(s):  
Additive Manufacturing ◽  
Thermoplastic Composites ◽  
Fiber Reinforced ◽  
Continuous Fiber

Mold technology for mass production of continuous fiber-reinforced sandwich parts

2016 ◽  
Vol 36 (6) ◽  
pp. 589-596 ◽  
Author(s):  
Christian Hopmann ◽  
Philipp N. Wagner ◽  
Robert Bastian ◽  
Kai Fischer ◽  
Arne Böttcher
Keyword(s):  
Systems Engineering ◽  
Composite Structures ◽  
Large Scale ◽  
Functional Integration ◽  
High Surface ◽  
Fiber Reinforced ◽  
Continuous Fiber ◽  
Short Cycle ◽  
Impregnation Process ◽  
Cycle Times

Abstract In order to reduce cycle times, increase functional integration and automation further, the innovative gap impregnation process and mold technology was developed at the Institute of Plastics Processing at RWTH Aachen University (Germany) in collaboration with industry partners. The novel process enables an automated production of continuous fiber-reinforced sandwich composite structures in integral design with high surface quality in short cycle times, which is demonstrated by manufacturing a carbon fiber-reinforced plastic (CFRP) engine hood. For the first time, the gap impregnation and mold technology makes it possible to manufacture large-scale, three-dimensionally shaped sandwich components in one shot and in short cycle times at similar mechanical properties compared to the reference steel hood. Furthermore, a weight reduction of about 60% to only 5 kg was achieved for the CFRP engine hood. This paper focuses on the systems engineering of the RTM-related gap impregnation process. The focus is on the utilized mold concepts for the pressurized air-assisted ejector pins, vacuum-tight sealing, the motion concept of the mold halves, resin traps, sensors for process control and the specially treated mold surfaces for class A surface components. Additionally, the main procedures, capabilities and characteristics of this innovative process are discussed.

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