A review on fibre reinforced composite printing via FFF

2019 ◽  
Vol 25 (6) ◽  
pp. 972-988 ◽  
Author(s):  
Isaac Ferreira ◽  
Margarida Machado ◽  
Fernando Alves ◽  
António Torres Marques
Keyword(s):  
High Performance ◽  
Mechanical Performance ◽  
Fused Filament Fabrication ◽  
Content Type ◽  
Performance Improvements ◽  
Different Types ◽  
Significant Research ◽  
Comprehensive Survey ◽  
3D Printed ◽  
Reinforced Thermoplastics

Purpose In industry, fused filament fabrication (FFF) offers flexibility and agility by promoting a reduction in costs and in the lead-time (i.e. time-to-market). Nevertheless, FFF parts exhibit some limitations such as lack of accuracy and/or lower mechanical performance. As a result, some alternatives have been developed to overcome some of these restrictions, namely, the formulation of high performance polymers, the creation of fibre-reinforced materials by FFF process and/or the design of new FFF-based technologies for printing composite materials. This work aims to analyze these technologies. Design/methodology/approach This work aims to study and understand the advances in the behaviour of 3D printed parts with enhanced performance by its reinforcement with several shapes and types of fibres from nanoparticles to continuous fibre roving. Thus, a comprehensive survey of significant research studies carried out regarding FFF of fibre-reinforced thermoplastics is provided, giving emphasis to the most relevant and innovative developments or adaptations undergone at hardware level and/or on the production process of the feedstock. Findings It is shown that the different types of reinforcement present different challenges for the printing process with different outcomes in the part performance. Originality/value This review is focused on joining the most important researches dedicated to the process of FFF-printed parts with different types reinforcing materials. By dividing the reinforcements in categories by shape/geometry and method of processing, it is possible to better quantify performance improvements.

scholarly journals Fabrication and Characterisation of Aligned Discontinuous Carbon Fibre Reinforced Thermoplastics as Feedstock Material for Fused Filament Fabrication

Materials ◽  
2020 ◽  
Vol 13 (20) ◽  
pp. 4671
Author(s):  
Lourens Blok ◽  
Marco Longana ◽  
Benjamin Woods
Keyword(s):  
High Performance ◽  
Mechanical Performance ◽  
Selection Process ◽  
Fibre Composite ◽  
Fibre Length ◽  
Fused Filament Fabrication ◽  
Continuous Fibre ◽  
And Performance ◽  
Reinforced Thermoplastics ◽  
High Level

In this work, aligned discontinuous fibre composite (ADFRC) tapes were developed and investigated as precursors for a novel 3D printing filament. ADFRCs have the potential to achieve mechanical performance comparable to continuous fibre reinforced composites, given sufficient fibre length and high level of alignment, and avoid many of the manufacturing difficulties associated with continuous fibres, e.g., wrinkling, bridging and corner radii constraints. Their potential use for fused filament fabrication (FFF) techniques was investigated here. An extensive down-selection process of thermoplastic matrices was performed, as matrix properties significantly impact both the processing and performance of the filament. This resulted in four candidate polymers (ABS, PLA, Nylon, PETG) which were used to manufacture ADFRC tapes with a Vf of 12.5% using the high performance discontinuous fibre (HiPerDiF) technology and an in-house developed continuous consolidation module. Tensile stiffness and strength up to 30 GPa and 400 MPa respectively were recorded, showing that a discontinuous fibre filament has the potential to compete with continuous fibre filaments.

Effect of nozzle diameter on mechanical and geometric performance of 3D printed carbon fibre-reinforced composites manufactured by fused filament fabrication

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Jesús Miguel Chacón ◽  
Miguel Ángel Caminero ◽  
Pedro José Núñez ◽  
Eustaquio García-Plaza ◽  
Jean Paul Bécar
Keyword(s):  
Surface Roughness ◽  
Carbon Fibre ◽  
Mechanical Performance ◽  
Dimensional Accuracy ◽  
Nozzle Diameter ◽  
Fused Filament Fabrication ◽  
Manufacturing Costs ◽  
Content Type ◽  
3D Printed ◽  
Composite Samples

Purpose Fused filament fabrication (FFF) is one of the most popular additive manufacturing (AM) technologies due to its ability to build thermoplastic parts with complex geometries at low cost. The FFF technique has been mainly used for rapid prototyping owing to the poor mechanical and geometrical properties of pure thermoplastic parts. However, both the development of new fibre-reinforced filaments with improved mechanical properties, and more accurate composite 3D printers have broadened the scope of FFF applications to functional components. FFF is a complex process with a large number of parameters influencing product quality and mechanical properties, and the effects of the combined parameters are usually difficult to evaluate. An array of parameter combinations has been analysed for improving the mechanical performance of thermoplastic parts such as layer thickness, build orientation, raster angle, raster width, air gap, infill density and pattern, fibre volume fraction, fibre layer location, fibre orientation and feed rate. This study aims to assess the effects of nozzle diameter on the mechanical performance and the geometric properties of 3D printed short carbon fibre-reinforced composites processed by the FFF technique. Design methodology approach Tensile and three-point bending tests were performed to characterise the mechanical response of the 3D printed composite samples. The dimensional accuracy, the flatness error and surface roughness of the printed specimens were also evaluated. Moreover, manufacturing costs, which are related to printing time, were evaluated. Finally, scanning electron microscopy images of the printed samples were analysed to estimate the porosity as a function of the nozzle diameter and to justify the effect of nozzle diameter on dimensional accuracy and surface roughness. Findings The effect of nozzle diameter on the mechanical and geometric quality of 3D printed composite samples was significant. In addition, large nozzle diameters tended to increase mechanical performance and enhance surface roughness, with a reduction in manufacturing costs. In contrast, 3D printed composite samples with small nozzle diameter exhibited higher geometric accuracy. However, the effect of nozzle diameter on the flatness error and surface roughness was of slight significance. Finally, some print guidelines are included. Originality value The effect of nozzle diameter, which is directly related to product quality and manufacturing costs, has not been extensively studied. The presented study provides more information regarding the dependence of the mechanical, microstructural and geometric properties of short carbon fibre-reinforced nylon composite components on nozzle diameter.

Fused filament printing of specialized biomedical devices: a state-of-the art review of technological feasibilities with PEEK

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Erfan Rezvani Ghomi ◽  
Saeideh Kholghi Eshkalak ◽  
Sunpreet Singh ◽  
Amutha Chinnappan ◽  
Seeram Ramakrishna ◽  
...  
Keyword(s):  
High Performance ◽  
State Of The Art ◽  
Three Dimensional ◽  
Patient Specific ◽  
Biomedical Devices ◽  
Fused Filament Fabrication ◽  
Content Type ◽  
Patient Specific Implants ◽  
Complex Design ◽  
Wide Range

Purpose The potential implications of the three-dimensional printing (3DP) technology are growing enormously in the various health-care sectors, including surgical planning, manufacturing of patient-specific implants and developing anatomical models. Although a wide range of thermoplastic polymers are available as 3DP feedstock, yet obtaining biocompatible and structurally integrated biomedical devices is still challenging owing to various technical issues. Design/methodology/approach Polyether ether ketone (PEEK) is an organic and biocompatible compound material that is recently being used to fabricate complex design geometries and patient-specific implants through 3DP. However, the thermal and rheological features of PEEK make it difficult to process through the 3DP technologies, for instance, fused filament fabrication. The present review paper presents a state-of-the-art literature review of the 3DP of PEEK for potential biomedical applications. In particular, a special emphasis has been given on the existing technical hurdles and possible technological and processing solutions for improving the printability of PEEK. Findings The reviewed literature highlighted that there exist numerous scientific and technical means which can be adopted for improving the quality features of the 3D-printed PEEK-based biomedical structures. The discussed technological innovations will help the 3DP system to enhance the layer adhesion strength, structural stability, as well as enable the printing of high-performance thermoplastics. Originality/value The content of the present manuscript will motivate young scholars and senior scientists to work in exploring high-performance thermoplastics for 3DP applications.

Temperature-compensated constitutive model of fused filament fabrication 3D printed PLA materials with full extrusion temperatures

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Kaiyang Zhu ◽  
Zichen Deng ◽  
Shi Dai ◽  
Yajun Yu
Keyword(s):  
Mechanical Properties ◽  
Thermal Decomposition ◽  
Constitutive Model ◽  
Polylactic Acid ◽  
Extrusion Temperature ◽  
Fused Filament Fabrication ◽  
Printing Process ◽  
Content Type ◽  
3D Printed ◽  
Interlayer Bonding

Purpose This study aims to focus on the effect of interlayer bonding and thermal decomposition on the mechanical properties of fused filament fabrication-printed polylactic acid specimens at high extrusion temperatures. Design/methodology/approach A printing process, that is simultaneous manufacturing of contour and specimen, is used to improve the printing accuracy at high extrusion temperatures. The effects of the extrusion temperature on the mechanical properties of the interlayer and intra-layer are evaluated via tensile experiments. In addition, the microstructure evolution affected by the extrusion temperature is observed using scanning electron microscopy. Findings The results show that the extrusion temperature can effectively improve the interlayer bonding property; however, the mechanical properties of the specimen for extrusion temperatures higher than 270°C may worsen owing to the thermal decomposition of the polylactic acid (PLA) material. The optimum extrusion temperature of PLA material in the three-dimensional (3D) printing process is recommended to be 250–270°C. Originality/value A temperature-compensated constitutive model for 3D printed PLA material under different extrusion temperatures is proposed. The present work facilitates the prediction of the mechanical properties of specimens at an extrusion temperature for different printing temperatures and different layers.

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.

Stiffness prediction of 3D printed fiber-reinforced thermoplastic composites

2019 ◽  
Vol 26 (3) ◽  
pp. 549-555
Author(s):  
Jin Young Choi ◽  
Mark Timothy Kortschot
Keyword(s):  
Mechanical Properties ◽  
Extrusion Direction ◽  
Analytical Models ◽  
Thermoplastic Composites ◽  
Fiber Reinforced ◽  
Flat Plates ◽  
Fused Filament Fabrication ◽  
Element Analysis ◽  
Content Type ◽  
3D Printed

Purpose The purpose of this study is to confirm that the stiffness of fused filament fabrication (FFF) three-dimensionally (3D) printed fiber-reinforced thermoplastic (FRP) materials can be predicted using classical laminate theory (CLT), and to subsequently use the model to demonstrate its potential to improve the mechanical properties of FFF 3D printed parts intended for load-bearing applications. Design/methodology/approach The porosity and the fiber orientation in specimens printed with carbon fiber reinforced filament were calculated from micro-computed tomography (µCT) images. The infill portion of the sample was modeled using CLT, while the perimeter contour portion was modeled with a rule of mixtures (ROM) approach. Findings The µCT scan images showed that a low porosity of 0.7 ± 0.1% was achieved, and the fibers were highly oriented in the filament extrusion direction. CLT and ROM were effective analytical models to predict the elastic modulus and Poisson’s ratio of FFF 3D printed FRP laminates. Research limitations/implications In this study, the CLT model was only used to predict the properties of flat plates. Once the in-plane properties are known, however, they can be used in a finite element analysis to predict the behavior of plate and shell structures. Practical implications By controlling the raster orientation, the mechanical properties of a FFF part can be optimized for the intended application. Originality/value Before this study, CLT had not been validated for FFF 3D printed FRPs. CLT can be used to help designers tailor the raster pattern of each layer for specific stiffness requirements.

On the use of high viscosity polymers in the fused filament fabrication process

2017 ◽  
Vol 23 (4) ◽  
pp. 727-735 ◽  
Author(s):  
Muhammad Hussam Khaliq ◽  
Rui Gomes ◽  
Célio Fernandes ◽  
João Nóbrega ◽  
Olga Sousa Carneiro ◽  
...  
Keyword(s):  
Mechanical Performance ◽  
High Viscosity ◽  
Polymer Processing ◽  
General Purpose ◽  
Good Choice ◽  
Fused Filament Fabrication ◽  
Content Type ◽  
Performance Requirements ◽  
Functional Prototype ◽  
The One

Purpose This work aims to provide additional insights regarding the practicability of using conventional materials in the fused filament fabrication (FFF) process. Design/methodology/approach Two different acrylonitryle butadiene styrene (ABS) grades are studied and compared, aiming to check to what extent the regular ABS developed for conventional polymer processing, with a different rheology than the one provided for the FFF process, can also be used in this process (FFF). Findings The rheological results show that a general-purpose ABS (ABS-GP) melt is much more viscous and elastic than ABS-FFF. It is clear that using ABS-GP as feedstock material in the FFF process results in poor coalescence and adhesion between the extruded filaments, which has a detrimental effect on the mechanical properties of the printed specimens. Despite its lower performance, ABS-GP can be a good choice if the objective is to produce an aesthetical prototype. If the objective is to produce a functional prototype or a final part, its mechanical performance requirements will dictate the choice. Originality/value This work provides insightful information regarding the use of high viscosity materials on the 3D printing process.

scholarly journals The Surface Characterisation of Fused Filament Fabricated (FFF) 3D Printed PEEK/Hydroxyapatite Composites

Polymers ◽  
2021 ◽  
Vol 13 (18) ◽  
pp. 3117
Author(s):  
Krzysztof Rodzeń ◽  
Mary Josephine McIvor ◽  
Preetam K. Sharma ◽  
Jonathan G. Acheson ◽  
Alistair McIlhagger ◽  
...  
Keyword(s):  
3D Printing ◽  
Photoelectron Spectroscopy ◽  
High Performance ◽  
Secondary Ion Mass Spectrometry ◽  
Fused Filament Fabrication ◽  
Surface Characterisation ◽  
X Ray ◽  
3D Printed

Polyetheretherketone (PEEK) is a high-performance thermoplastic polymer which has found increasing application in orthopaedics and has shown a lot of promise for ‘made-to-measure’ implants via additive manufacturing approaches. However, PEEK is bioinert and needs to undergo surface modification to make it at least osteoconductive to ensure a more rapid, improved, and stable fixation that will last longer in vivo. One approach to solving this issue is to modify PEEK with bioactive agents such as hydroxyapatite (HA). The work reported in this study demonstrates the direct 3D printing of PEEK/HA composites of up to 30 weight percent (wt%) HA using a Fused Filament Fabrication (FFF) approach. The surface characteristics and in vitro properties of the composite materials were investigated. X-ray diffraction revealed the samples to be semi-crystalline in nature, with X-ray Photoelectron Spectroscopy and Time-of-Flight Secondary Ion Mass Spectrometry revealing HA materials were available in the uppermost surface of all the 3D printed samples. In vitro testing of the samples at 7 days demonstrated that the PEEK/HA composite surfaces supported the adherence and growth of viable U-2 OS osteoblast like cells. These results demonstrate that FFF can deliver bioactive HA on the surface of PEEK bio-composites in a one-step 3D printing process.

Backpacker tourism: a perspective article

2019 ◽  
Vol 75 (1) ◽  
pp. 158-161
Author(s):  
Gang-Hua Chen ◽  
Songshan (Sam) Huang
Keyword(s):  
Future Development ◽  
Design Methodology ◽  
Tourism Research ◽  
Content Type ◽  
The Past ◽  
Research Themes ◽  
Different Types ◽  
The Future ◽  
Significant Research ◽  
Rapid Pace

Purpose This paper aims to contemplate the past development of backpacker tourism research and assess the future development of backpacker tourism research. Design/methodology/approach The authors evaluate the research on backpacker tourism in the past in the following three aspects, namely, research themes, research methods and geographical and cultural contexts of research. Findings Backpackers and backpacker tourism have been evolving in the past 75 years, just as other groups of travelers and forms of travel have. With the rapid pace of globalization in our time, backpacker tourism and its kinship forms will remain an important international tourism phenomenon, with root reasons in different types of economies and societies. As such, it will remain to be a significant research subject for tourism researchers in the future. Originality/value This paper contemplates the past development and assesses the future development of backpacker tourism research.

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