Anisotropic Material Behaviors of 3D Printed Carbon-Fiber Polymer Composites With Open-Source Printers

2021 ◽  
Author(s):  
Jordan Garcia ◽  
Robert Harper ◽  
Y. Charles Lu
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Carbon Fiber ◽  
3D Printing ◽  
Open Source ◽  
Polymer Composites ◽  
Mechanical Responses ◽  
Manufacturing Technique ◽  
3D Printed ◽  
Traditional Manufacturing

Abstract Composite products are often created using traditional manufacturing methods such as compression or injection molding. Recently, additive manufacturing (3D printing) techniques have been used for fabricating composites. 3D printing is the process of producing three-dimensional parts through the successive combination of various layers of material. This layering effect in combination with exposure to ambient (or reduced) temperature and pressure cause the finished products to have inconsistent microstructures. The inconsistent microstructures along with the oriented reinforcing fibers create anisotropic parts with difficulty to predict mechanical properties. In this paper, the mechanical properties of fiber reinforced polymer composites produced by additive manufacturing technique (3D printing) and by traditional manufacturing technique (compression molding) were investigated. Three open-source 3D printers, i.e. FlashForge Dreamer, Tevo Tornado, and Prusa i3 Mk3, were used to fabricate bending samples from carbon-fiber reinforced ABS (acrylonitrile butadiene styrene). Results showed that there exist significant discrepancies and anisotropies in mechanical properties of 3D printed composites. First, the properties vary greatly among parts made from different printers. Secondly, the mechanical responses of 3D printed parts strongly depend upon the orientations of the filaments. Parts with the infill oriented along the length of the specimens showed the most favorable mechanical responses such as Young’s modulus, maximum strength, and toughness. Thirdly, all 3D printed parts exhibit inferior properties to those made by conventional manufacturing. Finally, theoretical modeling has been attempted to predict the mechanical responses of 3D printed products and can potentially be used to “design” the 3D printing processes to achieve the optimal performance.

ANISOTROPIC MATERIAL BEHAVIORS OF 3D PRINTED CARBON-FIBER POLYMER COMPOSITES WITH OPEN-SOURCE PRINTERS

2021 ◽  
pp. 1-8
Author(s):  
Jordan Garcia ◽  
Robert Harper ◽  
Y. Charles Lu
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Carbon Fiber ◽  
3D Printing ◽  
Open Source ◽  
Polymer Composites ◽  
Mechanical Responses ◽  
Manufacturing Technique ◽  
3D Printed ◽  
Traditional Manufacturing

Abstract Composite products are often created using traditional manufacturing methods such as compression or injection molding. Recently, additive manufacturing (3D printing) techniques have been used for fabricating composites. 3D printing is the process of producing three-dimensional parts through the successive combination of various layers of material. This layering effect in combination with exposure to ambient (or reduced) temperature and pressure cause the finished products to have inconsistent microstructures. The inconsistent microstructures along with the oriented reinforcing fibers create anisotropic parts with difficulty to predict mechanical properties. In this paper, the mechanical properties of fiber reinforced polymer composites produced by additive manufacturing technique (3D printing) and by traditional manufacturing technique (compression molding) were investigated. Three open-source 3D printers, i.e. FlashForge Dreamer, Tevo Tornado, and Prusa i3 Mk3, were used to fabricate bending samples from carbon-fiber reinforced ABS (acrylonitrile butadiene styrene). Results showed that there exist significant discrepancies and anisotropies in mechanical properties of 3D printed composites. First, the properties vary greatly among parts made from different printers. Secondly, the mechanical responses of 3D printed parts strongly depend upon the orientations of the filaments. Parts with the infill oriented along the length of the specimens showed the most favorable mechanical responses such as Young's modulus, maximum strength, and toughness. Thirdly, all 3D printed parts exhibit inferior properties to those made by conventional manufacturing. Finally, theoretical modeling has been attempted to predict the mechanical responses of 3D printed products and can be used to “design” the 3D printing processes.

scholarly journals DLP 3D Printing Meets Lignocellulosic Biopolymers: Carboxymethyl Cellulose Inks for 3D Biocompatible Hydrogels

Polymers ◽  
2020 ◽  
Vol 12 (8) ◽  
pp. 1655 ◽  
Author(s):  
Giuseppe Melilli ◽  
Irene Carmagnola ◽  
Chiara Tonda-Turo ◽  
Fabrizio Pirri ◽  
Gianluca Ciardelli ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
3D Printing ◽  
Carboxymethyl Cellulose ◽  
Biomedical Applications ◽  
Digital Light Processing ◽  
Chemically Modified ◽  
Significant Step ◽  
3D Printed ◽  
Biomedical Field

The development of new bio-based inks is a stringent request for the expansion of additive manufacturing towards the development of 3D-printed biocompatible hydrogels. Herein, methacrylated carboxymethyl cellulose (M-CMC) is investigated as a bio-based photocurable ink for digital light processing (DLP) 3D printing. CMC is chemically modified using methacrylic anhydride. Successful methacrylation is confirmed by 1H NMR and FTIR spectroscopy. Aqueous formulations based on M-CMC/lithium phenyl-2,4,6-trimethylbenzoylphosphinate (LAP) photoinitiator and M-CMC/Dulbecco’s Modified Eagle Medium (DMEM)/LAP show high photoreactivity upon UV irradiation as confirmed by photorheology and FTIR. The same formulations can be easily 3D-printed through a DLP apparatus to produce 3D shaped hydrogels with excellent swelling ability and mechanical properties. Envisaging the application of the hydrogels in the biomedical field, cytotoxicity is also evaluated. The light-induced printing of cellulose-based hydrogels represents a significant step forward in the production of new DLP inks suitable for biomedical applications.

scholarly journals Property Analysis of Photo-Polymerization-Type 3D-Printed Structures Based on Multi-Composite Materials

2021 ◽  
Vol 11 (18) ◽  
pp. 8545
Author(s):  
So-Ree Hwang ◽  
Min-Soo Park
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Composite Materials ◽  
3D Printing ◽  
Bending Test ◽  
3D Printer ◽  
Complex Structures ◽  
Photo Polymerization ◽  
Anisotropic Structures ◽  
3D Printed

Additive manufacturing, commonly called 3D printing, has been studied extensively because it can be used to fabricate complex structures; however, polymer-based 3D printing has limitations in terms of implementing certain functionalities, so it is limited in the production of conceptual prototypes. As such, polymer-based composites and multi-material 3D printing are being studied as alternatives. In this study, a DLP 3D printer capable of printing multiple composite materials was fabricated using a movable separator and structures with various properties were fabricated by selectively printing two composite materials. After the specimen was fabricated based on the ASTM, the basic mechanical properties of the structure were compared through a 3-point bending test and a ball rebound test. Through this, it was shown that structures with various mechanical properties can be fabricated using the proposed movable-separator-based DLP process. In addition, it was shown that this process can be used to fabricate anisotropic structures, whose properties vary depending on the direction of the force applied to the structure. By fabricating multi-joint grippers with varying levels of flexibility, it was shown that the proposed process can be applied in the fabrication of soft robots as well.

scholarly journals Comparison between Tests and Simulations Regarding Bending Resistance of 3D Printed PLA Structures

Polymers ◽  
2021 ◽  
Vol 13 (24) ◽  
pp. 4371
Author(s):  
Dorin-Ioan Catana ◽  
Mihai-Alin Pop ◽  
Denisa-Iulia Brus
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
3D Printing ◽  
Process Parameters ◽  
Bending Stress ◽  
Test Results ◽  
Printing Process ◽  
Simulation Process ◽  
Bending Resistance ◽  
3D Printed

Additive manufacturing is one of the technologies that is beginning to be used in new fields of parts production, but it is also a technology that is constantly evolving, due to the advances made by researchers and printing equipment. The paper presents how, by using the simulation process, the geometry of the 3D printed structures from PLA and PLA-Glass was optimized at the bending stress. The optimization aimed to reduce the consumption of filament (material) simultaneously with an increase in the bending resistance. In addition, this paper demonstrates that the simulation process can only be applied with good results to 3D printed structures when their mechanical properties are known. The inconsistency of printing process parameters makes the 3D printed structures not homogeneous and, consequently, the occurrence of errors between the test results and those of simulations become natural and acceptable. The mechanical properties depend on the values of the printing process parameters and the printing equipment because, in the case of 3D printing, it is necessary for each combination of parameters to determine their mechanical properties through specific tests.

scholarly journals Parameters Affecting the Mechanical Properties of Three-Dimensional (3D) Printed Carbon Fiber-Reinforced Polylactide Composites

Polymers ◽  
2020 ◽  
Vol 12 (11) ◽  
pp. 2456
Author(s):  
Demei Lee ◽  
Guan-Yu Wu
Keyword(s):  
Mechanical Properties ◽  
Carbon Fiber ◽  
3D Printing ◽  
Three Dimensional ◽  
Fused Deposition Modelling ◽  
Layer By Layer ◽  
Fused Deposition ◽  
Bed Temperature ◽  
3D Printed ◽  
The Impact

Three-dimensional (3D) printing is a manufacturing technology which creates three-dimensional objects layer-by-layer or drop-by-drop with minimal material waste. Despite the fact that 3D printing is a versatile and adaptable process and has advantages in establishing complex and net-shaped structures over conventional manufacturing methods, the challenge remains in identifying the optimal parameters for the 3D printing process. This study investigated the influence of processing parameters on the mechanical properties of Fused Deposition Modelling (FDM)-printed carbon fiber-filled polylactide (CFR-PLA) composites by employing an orthogonal array model. After printing, the tensile and impact strengths of the printed composites were measured, and the effects of different parameters on these strengths were examined. The experimental results indicate that 3D-printed CFR-PLA showed a rougher surface morphology than virgin PLA. For the variables selected in this analysis, bed temperature was identified as the most influential parameter on the tensile strength of CFR-PLA-printed parts, while bed temperature and print orientation were the key parameters affecting the impact strengths of printed composites. The 45° orientation printed parts also showed superior mechanical strengths than the 90° printed parts.

scholarly journals Effect of Porosity and Crystallinity on 3D Printed PLA Properties

Polymers ◽  
2019 ◽  
Vol 11 (9) ◽  
pp. 1487 ◽  
Author(s):  
Yuhan Liao ◽  
Chang Liu ◽  
Bartolomeo Coppola ◽  
Giuseppina Barra ◽  
Luciano Di Maio ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Additive Manufacturing ◽  
3D Printing ◽  
Polylactic Acid ◽  
Complex Geometry ◽  
Fused Filament Fabrication ◽  
3D Printed ◽  
Physical Changes ◽  
Crystalline Forms

Additive manufacturing (AM) is a promising technology for the rapid tooling and fabrication of complex geometry components. Among all AM techniques, fused filament fabrication (FFF) is the most widely used technique for polymers. However, the consistency and properties control of the FFF product remains a challenging issue. This study aims to investigate physical changes during the 3D printing of polylactic acid (PLA). The correlations between the porosity, crystallinity and mechanical properties of the printed parts were studied. Moreover, the effects of the build-platform temperature were investigated. The experimental results confirmed the anisotropy of printed objects due to the occurrence of orientation phenomena during the filament deposition and the formation both of ordered and disordered crystalline forms (α and δ, respectively). A heat treatment post-3D printing was proposed as an effective method to improve mechanical properties by optimizing the crystallinity (transforming the δ form into the α one) and overcoming the anisotropy of the 3D printed object.

Mechanical Properties of 3D Printed Biomimicked Composites

2018 ◽  
Author(s):  
Seyed M. Allameh ◽  
Roger Miller ◽  
Hadi Allameh
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
3D Printing ◽  
Soft Materials ◽  
Structural Composites ◽  
Home Building ◽  
Complex Shapes ◽  
3D Printed ◽  
Bend Tests ◽  
Point Bend

Additive manufacturing technology has significantly matured over the last two decades. Recent progress in 3D printing has made it an attractive choice for fabricating complex shapes out of select materials possessing desirable properties at small and large scales. The application of biomimetics to the fabrication of structural composites has been shown to enhance their toughness and dynamic shear resistance. Building homes from bioinspired composites is possible if the process is automated. This can be achieved through additive manufacturing where layers of hard and soft materials can be deposited by 3D printing. This study examines mechanical properties of reinforced concrete fabricated by 3D printing. Preliminary results of 4-point bend tests are presented and the implications of 3D-printed home building on current conventional construction practices are discussed.

scholarly journals Additive Manufacturing in Customized Medical Device

2021 ◽  
Author(s):  
Ching Hang Bob Yung ◽  
Lung Fung Tse ◽  
Wing Fung Edmond Yau ◽  
Sze Yi Mak
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Medical Device ◽  
Three Dimensional ◽  
Medical Industry ◽  
New Era ◽  
Medical Needs ◽  
3D Printed ◽  
Traditional Manufacturing

The long-established application of rapid prototyping in additive manufacturing (AM) has inspired a revolution in the medical industry into a new era, in which the clinical-driven development of the customized medical device is enabled. This transformation could only be sustainable if clinical concerns could be well addressed. In this work, we propose a workflow that addresses critical clinical concerns such as translation from medical needs to product innovation, anatomical conformation and execution, and validation. This method has demonstrated outstanding advantages over the traditional manufacturing approach in terms of form, function, precision, and clinical flexibility. We further propose a protocol for the validation of biocompatibility, material, and mechanical properties. Finally, we lay out a roadmap for AM-driven customized medical device innovation based on our experiences in Hong Kong, addressing problems of certification, qualification, characterization of three dimensional (3D) printed implants according to medical demands.

scholarly journals 3D-Printed Carbon Fiber Reinforced Polymer Composites: A Systematic Review

2020 ◽  
Vol 4 (3) ◽  
pp. 98 ◽  
Author(s):  
Seyed Hamid Reza Sanei ◽  
Diana Popescu
Keyword(s):  
Mechanical Properties ◽  
Carbon Fiber ◽  
3D Printing ◽  
Fiber Orientation ◽  
Fiber Reinforced Composites ◽  
Carbon Fiber Composites ◽  
Reinforced Composites ◽  
Fiber Reinforced ◽  
3D Printed ◽  
Carbon Fiber Reinforced

Fiber reinforced composites offer exceptional directional mechanical properties, and combining their advantages with the capability of 3D printing has resulted in many innovative research fronts. This review aims to summarize the methods and findings of research conducted on 3D-printed carbon fiber reinforced composites. The review is focused on commercially available printers and filaments, as their results are reproducible and the findings can be applied to functional parts. As the process parameters can be readily changed in preparation of a 3D-printed part, it has been the focus of many studies. In addition to typical composite driving factors such as fiber orientation, fiber volume fraction and stacking sequence, printing parameters such as infill density, infill pattern, nozzle speed, layer thickness, built orientation, nozzle and bed temperatures have shown to influence mechanical properties. Due to the unique advantages of 3D printing, in addition to conventional unidirectional fiber orientation, concentric fiber rings have been used to optimize the mechanical performance of a part. This review surveys the literature in 3D printing of chopped and continuous carbon fiber composites to provide a reference for the state-of-the-art efforts, existing limitations and new research frontiers.

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