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.

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.

Mechanical benchmarking of additively manufactured continuous and short carbon fiber reinforced nylon

2021 ◽  
pp. 002199832110200
Author(s):  
Mahdi Mohammadizadeh ◽  
Ankit Gupta ◽  
Ismail Fidan
Keyword(s):  
Mechanical Properties ◽  
Morphological Analysis ◽  
Fiber Composite ◽  
Fiber Reinforced ◽  
Fused Filament Fabrication ◽  
Compression Properties ◽  
Pull Out ◽  
Fiber Size ◽  
3D Printed ◽  
Short Carbon

Mechanical properties of fiber reinforced additive manufacturing (FRAM) parts are affected by the fiber size and orientation. Oriented fiber composite is most likely to produce better properties. The objective of this research is to perform a comparative analysis of the mechanical properties of short and continuous fiber reinforced nylon 6 produced with fused filament fabrication (FFF) technology. In this study, it was observed that tensile, compression and flexural properties are significantly affected by the change in the fiber length and orientation. Scanning electron microscopy (SEM) was performed after mechanical testing to observe the influence of fiber on the final properties. From the testing, it was observed that continuous-FRAM (C-FRAM) parts show better properties in tensile loading and short-FRAM (S-FRAM) in bending. S-FRAM parts show better improvement in flexural and compression properties as compared to CFRAM parts. Morphological analysis of tested 3D-printed parts concluded that the fiber-pull out and fiber breakage are the main failure mechanisms.

scholarly journals Fused Filament Fabrication of Polymers and Continuous Fiber-Reinforced Polymer Composites: Advances in Structure Optimization and Health Monitoring

Polymers ◽  
2021 ◽  
Vol 13 (5) ◽  
pp. 789
Author(s):  
Fatemeh Mashayekhi ◽  
Julien Bardon ◽  
Vincent Berthé ◽  
Henri Perrin ◽  
Stephan Westermann ◽  
...  
Keyword(s):  
Health Monitoring ◽  
Thermoplastic Composites ◽  
Fiber Reinforced ◽  
Continuous Fiber ◽  
Fused Filament Fabrication ◽  
Thermoplastic Matrix ◽  
Fiber Reinforced Polymer Composites ◽  
3D Printed ◽  
Printed Materials ◽  
Monitoring Technologies

3D printed neat thermoplastic polymers (TPs) and continuous fiber-reinforced thermoplastic composites (CFRTPCs) by fused filament fabrication (FFF) are becoming attractive materials for numerous applications. However, the structure of these materials exhibits interfaces at different scales, engendering non-optimal mechanical properties. The first part of the review presents a description of these interfaces and highlights the different strategies to improve interfacial bonding. The actual knowledge on the structural aspects of the thermoplastic matrix is also summarized in this contribution with a focus on crystallization and orientation. The research to be tackled to further improve the structural properties of the 3D printed materials is identified. The second part of the review provides an overview of structural health monitoring technologies relying on the use of fiber Bragg grating sensors, strain gauge sensors and self-sensing. After a brief discussion on these three technologies, the needed research to further stimulate the development of FFF is identified. Finally, in the third part of this contribution the technology landscape of FFF processes for CFRTPCs is provided, including the future trends.

scholarly journals Evaluation of the Infill Design on the Tensile Response of 3D Printed Polylactic Acid Polymer

Materials ◽  
2021 ◽  
Vol 14 (9) ◽  
pp. 2195
Author(s):  
Tanner David Harpool ◽  
Ibrahim Mohammed Alarifi ◽  
Basheer A. Alshammari ◽  
Abdul Aabid ◽  
Muneer Baig ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Tensile Stress ◽  
Polylactic Acid ◽  
Solid Substrate ◽  
Ultimate Tensile Stress ◽  
Experimental Results ◽  
Fused Filament Fabrication ◽  
Element Analysis ◽  
Cross Sectional ◽  
3D Printed

The current study explores the effects of geometrical shapes of the infills on the 3D printed polylactic acid (PLA) plastic on the tensile properties. For this purpose, by utilizing an accessible supply desktop printer, specimens of diamond, rectangular, and hexagonal infill patterns were produced using the fused filament fabrication (FFF) 3D printing technique. Additionally, solid samples were printed for comparison. The printed tensile test specimens were conducted at environmental temperature, Ta of 23 °C and crosshead speed, VC.H of 5 mm/min. Mainly, this study focuses on investigating the percentage infill with respect to the cross-sectional area of the investigated samples. The mechanical properties, i.e., modulus of toughness, ultimate tensile stress, yield stress, and percent elongation, were explored for each sample having a different geometrical infill design. The test outcomes for each pattern were systematically compared. To further validate the experimental results, a computer simulation using finite element analysis was also performed and contrasted with the experimental tensile tests. The experimental results mainly suggested a brittle behavior for solidly infilled specimen, while rectangular, diamond, and hexagonal infill patterns showed ductile-like behavior (fine size and texture of infills). This brittleness may be due to the relatively higher infill density results that led to the high bonding adhesion of the printed layers, and the size and thickness effects of the solid substrate. It made the solidly infilled specimen structure denser and brittle. Among all structures, hexagon geometrical infill showed relative improvement in the mechanical properties (highest ultimate tensile stress and modulus values 1759.4 MPa and 57.74 MPa, respectively) compared with other geometrical infills. Therefore, the geometrical infill effects play an important role in selecting the suitable mechanical property’s values in industrial applications.

scholarly journals Three-Dimensional Printing of Continuous Flax Fiber-Reinforced Thermoplastic Composites by Five-Axis Machine

Materials ◽  
2020 ◽  
Vol 13 (7) ◽  
pp. 1678 ◽  
Author(s):  
Haiguang Zhang ◽  
Di Liu ◽  
Tinglong Huang ◽  
Qingxi Hu ◽  
Herfried Lammer
Keyword(s):  
Natural Fiber ◽  
Three Dimensional ◽  
Flax Fiber ◽  
Thermoplastic Composites ◽  
3D Printer ◽  
Fiber Reinforced ◽  
Fused Filament Fabrication ◽  
Reinforced Plastic ◽  
3D Printed ◽  
Five Axis

A method for printing continuous flax fiber-reinforced plastic (CFFRP) composite parts by five-axis three-dimensional (3D) printer, based on fused filament fabrication (FFF) technology, has been developed. FFF printed parts usually need supporting structures, have a stair step effect, and unfavorable mechanical properties. In order to address these deficiencies, continuous natural fiber prepreg filaments were first manufactured, followed by curved path planning for the model for generation of the G-code, and finally printed by a five-axis 3D printer. The surface quality of printed parts was greatly improved. The tensile strength and modulus of CFFRP increased by 89% and 73%, respectively, compared with polylactic acid (PLA) filaments. The flexural strength and modulus of the 3D-printed CFFRP specimens increased by 211% and 224%, respectively, compared with PLA specimens. The maximal curved bending force load and stiffness of the 3D-printed CFFRP specimens increased by 39% and 115%, respectively, compared with the flat slicing method. Advanced light structures, such as leaf springs, can be designed and manufactured by taking advantage of the favorable properties of these composites, which endow them with significant potential for application in the field of automobiles.

Correlation of tribo-mechanical properties of internal geometry structures of fused filament fabrication 3D-printed acrylonitrile butadiene styrene

2020 ◽  
Vol 72 (10) ◽  
pp. 1259-1265
Author(s):  
Mohamad Nordin Mohamad Norani ◽  
Mohd Fadzli Bin Abdollah ◽  
Muhammad Ilman Hakimi Chua Abdullah ◽  
Hilmi Amiruddin ◽  
Faiz Redza Ramli ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Wear Rate ◽  
Peer Review ◽  
Tribological Properties ◽  
Acrylonitrile Butadiene Styrene ◽  
Fused Filament Fabrication ◽  
Content Type ◽  
Internal Geometry ◽  
3D Printed ◽  
Butadiene Styrene

Purpose This study aims is to investigate the correlation between tribological and mechanical properties of the fused filament fabrication 3D-printed acrylonitrile butadiene styrene (ABS) pin with different internal geometries. Design/methodology/approach The tribological properties were determined by a dry sliding test with constant test parameters, while the hardness and modulus of elasticity were determined by microhardness and compression tests. Findings Although the internal geometry of the pin sample slightly affects the coefficient of friction (COF) and the wear rate of the 3D-printed ABS, it was important to design a lightweight tribo-component by reducing the material used to save energy without compromising the strength of the component. The COF and wear rate values are relatively dependent on the elastic modulus. A 3D-printed ABS pin with an internal triangular flip structure was found to have the shortest run-in period and the lowest COF with high wear resistance. Abrasive wear and delamination are the predominant wear mechanisms involved. Research limitations/implications The findings are the subject of future research under various sliding conditions by investigating the synergistic effect of sliding speeds and applied loads to validate the results of this study. Originality/value The internal structure affects the mechanical properties and release stress concentration at the contact point, resulting in hypothetically low friction and wear. This approach may also reduce the weight of the parts without scarifying or at least preserving their preceding tribological performance. Therefore, based on our knowledge, limited studies have been conducted for the application of 3D printing in tribology, and most studies focused on improving their mechanical properties rather than correlating them with tribological properties that would benefit longer product lifespans. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-04-2020-0143/

scholarly journals Generation of Wholly Thermoplastic Composites and Their Processing in Additive Manufacturing

2021 ◽  
Author(s):  
Tianran Chen
Keyword(s):  
Mechanical Properties ◽  
3D Printing ◽  
High Performance ◽  
Liquid Crystalline ◽  
Mechanical Performance ◽  
Crystalline Polymer ◽  
Extrusion Process ◽  
Thermoplastic Composites ◽  
Fiber Reinforced ◽  
Fused Filament Fabrication

3D printing has attracted great interest over the past three decades due to its high precision, less waste generation and design freedom [1-3]. One of the major challenges 3D printing is the poor mechanical performance of pure polymer parts. Researchers used traditional carbon and glass fiber reinforced composites to overcome this issue [4-7]. The traditional fibers can improve the mechanical properties of printed parts. However, the manufacturing techniques and printing process restrict the overall performance of the printed parts. Thermotropic liquid crystalline polymer (TLCP) is another reinforcement which offers lighter weight, lower viscosity, excellent mechanical performance and great recyclability [8-15]. TLCPs are capable of forming extended conformations when subjected to extensional or shear deformation.[16, 17] The formation of highly orientated molecular structure enables the generation of high mechanical properties. In this study, polyamide was reinforced with TLCP by the dual-extrusion technique to generate high performance composite filaments [18]. Rheological tests were used to optimize the processing conditions of the dual-extrusion process, which could minimize the degradation of matrix polymer. High performance and lightweight fiber-reinforced composite parts were fabricated by utilizing the fused filament fabrication (FFF) technique. The composite filaments were printed at the temperature below the melting point of TLCP to avoid the relaxation of TLCP. The mechanical performances of printed parts are greater than 3D printed parts which are reinforced by conventional fibers.

scholarly journals Generation of Wholly Thermoplastic Composites and Their Processing in Additive Manufacturing

2021 ◽  
Author(s):  
Tianran Chen ◽  
Donald Baid
Keyword(s):  
Mechanical Properties ◽  
3D Printing ◽  
High Performance ◽  
Liquid Crystalline ◽  
Mechanical Performance ◽  
Crystalline Polymer ◽  
Extrusion Process ◽  
Thermoplastic Composites ◽  
Fiber Reinforced ◽  
Fused Filament Fabrication

3D printing has attracted great interest over the past three decades due to its high precision, less waste generation and design freedom[1-3]. One of the major challenges 3D printing is the poor mechanical performance of pure polymer parts. Researchers used traditional carbon and glass fiber reinforced composites to overcome this issue [4-7]. The traditional fibers can improve the mechanical properties of printed parts. However, the manufacturing techniques and printing process restrict the overall performance of the printed parts. Thermotropic liquid crystalline polymer (TLCP) is another reinforcement which offers lighter weight, lower viscosity, excellent mechanical performance and great recyclability [8-15]. TLCPs are capable of forming extended conformations when subjected to extensional or shear deformation.[16, 17] The formation of highly orientated molecular structure enables the generation of high mechanical properties . In this study, polyamide was reinforced with TLCP by the dual-extrusion technique to generate high performance composite filaments [18]. Rheological tests were used to optimize the processing conditions of the dual-extrusion process, which could minimize the degradation of matrix polymer. High performance and lightweight fiber-reinforced composite parts were fabricated by utilizing the fused filament fabrication (FFF) technique. The composite filaments were printed at the temperature below the melting point of TLCP to avoid the relaxation of TLCP. The mechanical performances of printed parts are greater than 3D printed parts which are reinforced by conventional fibers.

Impacts of thermoplastics content on mechanical properties of continuous fiber-reinforced thermoplastic composites

2021 ◽  
Vol 216 ◽  
pp. 108859
Author(s):  
Dong-Jun Kwon ◽  
Neul-Sae-Rom Kim ◽  
Yeong-Jin Jang ◽  
Hyun Ho Choi ◽  
Kihyun Kim ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Thermoplastic Composites ◽  
Fiber Reinforced ◽  
Continuous Fiber
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