scholarly journals Mechanical Performance of Long-fibre Reinforced Polymer Composites by 3D Printing

2020 ◽  
Author(s):  
Francis Dantas ◽  
Greg Gibbons
Keyword(s):  
3D Printing ◽  
Polymer Composites ◽  
Mechanical Response ◽  
Mechanical Performance ◽  
Fibre Composite ◽  
Flexural Modulus ◽  
Matrix Material ◽  
Base Material ◽  
Fibre Reinforcement ◽  
Number Of Layers

Abstract Additive Manufacturing (AM), also known as 3D Printing, has been around for more than 2 decades and has recently gained importance for use in direct manufacturing. The quantified physical properties of materials are required by design engineers to inform and validate their designs, and this is no less true for AM that it is for traditional manufacturing methods. Recent innovation in AM has seen the emergence of long-fibre composite AM technologies, such as the Mark Two (Markforged Inc, USA) system, enabling the manufacture of thermoplastic polymer composites with long-fibre reinforcement. To date though, the mechanical response of the materials with respect to build parameter variation is little understood. In this project, selected mechanical properties (ultimate tensile strength – UTS and flexural modulus) of samples processed using the Mark Two printer were studied. The effect of the reinforcement type (Carbon, Kevlar®, and HSHT glass), amount of reinforcement, reinforcement lay-up orientation, and the base matrix material (Onyx and polyamide) on these properties were assessed using accepted standard test methods. For Onyx, the UTS and Flexural Modulus was improved by a maximum of 244 ± 10 MPa (1228 ± 19%) and 14.2 ± 0.3 GPa (1114 ± 6%) (Carbon), by 143 ± 1 MPa (721 ± 18%) and 7.1 ± 0.3 GPa (560 ± 6%) (Kevlar®) and 209 ± 4 MPa (1049 ± 19%) and 6.0 ± 0.1 GPa (469 ± 6%) (HSHT glass). For Nylon the UTS and Flexural Modulus was improved by 235 ± 4 MPa (1431 ± 56%) and 14.1 ± 0.2 GPa (1924 ± 5%) (Carbon), 143 ± 3 MPa (867 ± 56%) and 6.79 ± 0.08 GPa (927 ± 5%) (Kevlar®) and 204 ± 2 MPa (1250 ± 55%) and 5.73 ± 0.09 GPa (782 ± 5%) (HSHT glass). A regression and ANOVA analysis for UTS indicated that the number of layers of reinforcement had the largest impact on UTS (F = 11,483 P < 0.005), with the second most important parameter being the type of reinforcement (F = 855 P < 0.005). The parameter effects for all four parameters were significant (P ≤ 0.05). For the Flexural Modulus, the number of layers of reinforcement was again the most significant parameter (F = 2733 P < 0.005), with the second most important parameter again being the type of reinforcement (F = 1339 P < 0.005). Again, the parameter effects for all four parameters were significant (P ≤ 0.05), although the influence of base material had much less significant effect on determining the Flexural Modulus than it did in controlling UTS.

scholarly journals Long-fibre reinforced polymer composites by 3D printing: influence of nature of reinforcement and processing parameters on mechanical performance

2020 ◽  
Vol 1 (1) ◽  
Author(s):  
Francis Dantas ◽  
Kevin Couling ◽  
Gregory J. Gibbons
Keyword(s):  
Carbon Fibre ◽  
Polymer Composites ◽  
Mechanical Performance ◽  
Flexural Modulus ◽  
Matrix Material ◽  
Processing Parameters ◽  
Fibre Reinforcement ◽  
Reinforced Polymer ◽  
Unreinforced Material ◽  
Fibre Reinforced Polymer

Abstract The aim of this study was to identify the effect of material type (matrix and reinforcement) and process parameters, on the mechanical properties of 3D Printed long-fibre reinforced polymer composites manufactured using a commercial 3D Printer (Mark Two). The effect of matrix material (Onyx or polyamide), reinforcement type (Carbon, Kevlar®, and HSHT glass), volume of reinforcement, and reinforcement lay-up orientation on both Ultimate Tensile Strength (UTS) and Flexural Modulus were investigated. For Onyx, carbon fibre reinforcement offered the largest increase in both UTS and Flexural Modulus over unreinforced material (1228 ± 19% and 1114 ± 6% respectively). Kevlar® and HSHT also provided improvements but these were less significant. Similarly, for Nylon, the UTS and Flexural Modulus were increased by 1431 ± 56% and 1924 ± 5% by the addition of carbon fibre reinforcement. Statistical analysis indicated that changing the number of layers of reinforcement had the largest impact on both UTS and Flexural Strength, and all parameters were statistically significant.

scholarly journals Long-fibre Reinforced Polymer Composites by 3D Printing: Influence of Nature of Reinforcement and Processing Parameters on Mechanical Performance

2020 ◽  
Author(s):  
Francis Dantas ◽  
Kevin Couling ◽  
Greg Gibbons
Keyword(s):  
Carbon Fibre ◽  
Polymer Composites ◽  
Mechanical Performance ◽  
Flexural Modulus ◽  
Matrix Material ◽  
Processing Parameters ◽  
Fibre Reinforcement ◽  
Reinforced Polymer ◽  
Unreinforced Material ◽  
Fibre Reinforced Polymer

Abstract The aim of this study was to identify the effect of material type (matrix and reinforcement) and process parameters, on the mechanical properties of 3D Printed long-fibre reinforced polymer composites manufactured using a commercial 3D Printer (Mark Two). The effect of matrix material (Onyx or polyamide), reinforcement type (Carbon, Kevlar®, and HSHT glass), volume of reinforcement, and reinforcement lay-up orientation on both Ultimate Tensile Strength (UTS) and Flexural Modulus were investigated. For Onyx, carbon fibre reinforcement offered the largest increase in both UTS and Flexural Modulus over unreinforced material (1,228±19 % and 1,114±6 % respectively). Kevlar® and HSHT also provided improvements but these were less significant. Similarly, for Nylon, the UTS and Flexural Modulus were increased by 1,431±56 % and 1,924±5 % by the addition of carbon fibre reinforcement. Statistical analysis indicated that changing the number of layers of reinforcement had the largest impact on both UTS and Flexural Strength, and all parameters were statistically significant.

scholarly journals Investigation of the Biocidal Performance of Multi-Functional Resin/Copper Nanocomposites with Superior Mechanical Response in SLA 3D Printing

Biomimetics ◽  
2022 ◽  
Vol 7 (1) ◽  
pp. 8
Author(s):  
Nectarios Vidakis ◽  
Markos Petousis ◽  
Emmanuel Velidakis ◽  
Nikolaos Mountakis ◽  
Dimitris Tsikritzis ◽  
...  
Keyword(s):  
3D Printing ◽  
Mechanical Response ◽  
Mechanical Performance ◽  
Matrix Material ◽  
International Standards ◽  
Added Value ◽  
Diffusion Method ◽  
Host Defense Peptides ◽  
Antibacterial Performance ◽  
Biocidal Properties

Metals, such as silver, gold, and copper are known for their biocidal properties, mimicking the host defense peptides (HDPs) of the immune system. Developing materials with such properties has great importance in medicine, especially when combined with 3D printing technology, which is an additional asset for various applications. In this work, copper nanoparticles were used as filler in stereolithography (SLA) ultraviolet (UV) cured commercial resin to induce such biocidal properties in the material. The nanocomposites developed featured enhanced mechanical responses when compared with the neat material. The prepared nanocomposites were employed to manufacture specimens with the SLA process, to be tested for their mechanical response according to international standards. The process followed was evaluated with Scanning Electron Microscopy (SEM), Atomic Force Microscopy (AFM), energy-dispersive X-ray spectroscopy (EDS), and thermogravimetric analysis (TGA). The antibacterial activity of the fabricated nanocomposites was evaluated using the agar-well diffusion method. Results showed enhanced mechanical performance of approximately 33.7% in the tensile tests for the nanocomposites filled with 1.0 wt.%. ratios, when compared to the neat matrix material, while this loading showed sufficient antibacterial performance when compared to lower filler loadings, providing an added value for the fabrication of effective nanocomposites in medical applications with the SLA process.

scholarly journals 3D Printing of Fibre-Reinforced Thermoplastic Composites Using Fused Filament Fabrication—A Review

Polymers ◽  
2020 ◽  
Vol 12 (10) ◽  
pp. 2188
Author(s):  
Andrew N. Dickson ◽  
Hisham M. Abourayana ◽  
Denis P. Dowling
Keyword(s):  
3D Printing ◽  
Polymer Composites ◽  
Mechanical Performance ◽  
Polymer Processing ◽  
Thermoplastic Composites ◽  
Fused Filament Fabrication ◽  
Compression Moulding ◽  
Processing Technologies ◽  
Reinforced Polymer ◽  
Fibre Reinforced Polymer

Three-dimensional (3D) printing has been successfully applied for the fabrication of polymer components ranging from prototypes to final products. An issue, however, is that the resulting 3D printed parts exhibit inferior mechanical performance to parts fabricated using conventional polymer processing technologies, such as compression moulding. The addition of fibres and other materials into the polymer matrix to form a composite can yield a significant enhancement in the structural strength of printed polymer parts. This review focuses on the enhanced mechanical performance obtained through the printing of fibre-reinforced polymer composites, using the fused filament fabrication (FFF) 3D printing technique. The uses of both short and continuous fibre-reinforced polymer composites are reviewed. Finally, examples of some applications of FFF printed polymer composites using robotic processes are highlighted.

Mechanical performance of hybrid woven jute–roselle-reinforced polyester composites

2019 ◽  
Vol 27 (7) ◽  
pp. 407-418 ◽  
Author(s):  
Mohammad Hazim Mohamad Hamdan ◽  
Januar Parlaungan Siregar ◽  
Sabu Thomas ◽  
Maya John Jacob ◽  
Jamiluddin Jaafar ◽  
...  
Keyword(s):  
Composite Plate ◽  
Synthetic Fibre ◽  
Mechanical Performance ◽  
Flexural Modulus ◽  
Natural Fibre ◽  
Impact Testing ◽  
Void Content ◽  
Fibre Reinforcement ◽  
Pull Out ◽  
The Impact

Natural fibre acts as a significant replacement for the known synthetic fibre that tends to cause critical environmental issues. Hence, the hybridization of natural fibre reinforcement has been considered as one of the strategies in reducing synthetic fibre applications. The current research was conducted to determine the effect of layering sequence on the mechanical performance of hybrid woven jute–roselle. In addition, eight different types of composite plate that consisted of single and hybrid were fabricated through the implementation of hand lay-up method. In this case, each composite plate had to undergo the tensile, flexural and impact testing in order to acquire the effect of varying layering sequences. The results of the present study showed that the hybridization of jute–roselle provided was significant, especially on the flexural and impact performance. Furthermore, the tensile strength and modulus were higher on the JRRJ sample and maximum flexural strength also managed to be recorded by the same sample. However, the maximum flexural modulus only managed to be recorded in sample RRJJ. Meanwhile, the impact testing revealed that the composite plate of sample JJRR had the highest impact strength. The void content for all the samples was acceptable because all of them were less than 7%. Finally, scanning electron microscopic image illustrated that the fractured surfaced of composite sample was typically smooth with less formation of void and fibre pull-out.

scholarly journals A Novel Route to Fabricate High-Performance 3D Printed Continuous Fiber-Reinforced Thermosetting Polymer Composites

Materials ◽  
2019 ◽  
Vol 12 (9) ◽  
pp. 1369 ◽  
Author(s):  
Yueke Ming ◽  
Yugang Duan ◽  
Ben Wang ◽  
Hong Xiao ◽  
Xiaohui Zhang
Keyword(s):  
3D Printing ◽  
Polymer Composites ◽  
High Performance ◽  
Flexural Modulus ◽  
Shape Preservation ◽  
Fiber Reinforced ◽  
Continuous Fiber ◽  
Research Attention ◽  
3D Printed ◽  
Thermosetting Polymer

Recently, 3D printing of fiber-reinforced composites has gained significant research attention. However, commercial utilization is limited by the low fiber content and poor fiber–resin interface. Herein, a novel 3D printing process to fabricate continuous fiber-reinforced thermosetting polymer composites (CFRTPCs) is proposed. In brief, the proposed process is based on the viscosity–temperature characteristics of the thermosetting epoxy resin (E-20). First, the desired 3D printing filament was prepared by impregnating a 3K carbon fiber with a thermosetting matrix at 130 °C. The adhesion and support required during printing were then provided by melting the resin into a viscous state in the heating head and rapidly cooling after pulling out from the printing nozzle. Finally, a powder compression post-curing method was used to accomplish the cross-linking reaction and shape preservation. Furthermore, the 3D-printed CFRTPCs exhibited a tensile strength and tensile modulus of 1476.11 MPa and 100.28 GPa, respectively, a flexural strength and flexural modulus of 858.05 MPa and 71.95 GPa, respectively, and an interlaminar shear strength of 48.75 MPa. Owing to its high performance and low concentration of defects, the proposed printing technique shows promise in further utilization and industrialization of 3D printing for different applications.

scholarly journals On the Mechanical Response of Silicon Dioxide Nanofiller Concentration on Fused Filament Fabrication 3D Printed Isotactic Polypropylene Nanocomposites

Polymers ◽  
2021 ◽  
Vol 13 (12) ◽  
pp. 2029
Author(s):  
Nectarios Vidakis ◽  
Markos Petousis ◽  
Emmanouil Velidakis ◽  
Lazaros Tzounis ◽  
Nikolaos Mountakis ◽  
...  
Keyword(s):  
3D Printing ◽  
Silicon Dioxide ◽  
Mechanical Response ◽  
Mechanical Performance ◽  
Microstructural Analysis ◽  
Melt Flow Index ◽  
International Standards ◽  
Flow Index ◽  
Fused Filament Fabrication ◽  
Melt Mixing

Utilization of advanced engineering thermoplastic materials in fused filament fabrication (FFF) 3D printing process is critical in expanding additive manufacturing (AM) applications. Polypropylene (PP) is a widely used thermoplastic material, while silicon dioxide (SiO2) nanoparticles (NPs), which can be found in many living organisms, are commonly employed as fillers in polymers to improve their mechanical properties and processability. In this work, PP/SiO2 nanocomposite filaments at various concentrations were developed following a melt mixing extrusion process, and used for FFF 3D printing of specimens’ characterization according to international standards. Tensile, flexural, impact, microhardness, and dynamic mechanical analysis (DMA) tests were conducted to determine the effect of the nanofiller loading on the mechanical and viscoelastic properties of the polymer matrix. Scanning electron microscopy (SEM), Raman spectroscopy and atomic force microscopy (AFM) were performed for microstructural analysis, and finally melt flow index (MFI) tests were conducted to assess the melt rheological properties. An improvement in the mechanical performance was observed for silica loading up to 2.0 wt.%, while 4.0 wt.% was a potential threshold revealing processability challenges. Overall, PP/SiO2 nanocomposites could be ideal candidates for advanced 3D printing engineering applications towards structural plastic components with enhanced mechanical performance.

Mechanical behaviour of 3D printed Lightweight Nano-composites

2021 ◽  
Vol 06 ◽  
Author(s):  
Mrityunjay Doddamani
Keyword(s):  
Polymer Composites ◽  
Mechanical Performance ◽  
Flexural Modulus ◽  
Substantial Reduction ◽  
Nano Composites ◽  
3 Dimensional ◽  
Single Screw Extruder ◽  
Flexural Testing ◽  
3D Printed ◽  
Traditional Processing

Background: The nanoclay (NC) and glass micro balloons (GMB) based reinforced polymer composites are explored extensively through traditional processing methods. NC shows substantial enhancement in mechanical properties. Polymer composites developed by reinforcing GMB fillers provide a substantial reduction in weight, which is essential in the marine, aerospace, and automotive field. In this study, an attempt is made by developing polymer nano composites by reinforcing NC and GMB particles. Objective: The paper deals with 3 dimensional printing (3DP) of lightweight nanocomposite foam (NF) developed by mixing nanoclay (NC) and glass micro balloons (GMB) in high-density polyethylene (HDPE). The NF blend is prepared by keeping NC at 5 weight %. Subsequently, GMBs are added by volume (20 - 60 %) to NC/HDPE blend to realize lightweight NFs. Methods: The lightweight feedstock filaments are developed by extruding the blends using a single screw extruder. The extruded NF filaments are used as an input in a 3D printer to print NFs. The density of extruded filaments and prints are measured. The printed NFs are subjected to tensile and flexural testing. Conclusion: With an increase in GMB loading the density of both filaments and prints decreases. Compared to neat HDPE, printed NFs show ~30 % weight reducing potential. The tensile, flexural modulus and strength increases with GMB loading. NFs exhibited superior mechanical performance as compared to HDPE and NC/HDPE. Further, the property map reveals that the 3D printed NFs show superior tensile, flexural modulus, and strength in comparison with injection and compression-molded foams.

scholarly journals Mechanical Performance of Fused Filament Fabricated and 3D-Printed Polycarbonate Polymer and Polycarbonate/Cellulose Nanofiber Nanocomposites

Fibers ◽  
2021 ◽  
Vol 9 (11) ◽  
pp. 74
Author(s):  
Nectarios Vidakis ◽  
Markos Petousis ◽  
Emmanouil Velidakis ◽  
Mariza Spiridaki ◽  
John D. Kechagias
Keyword(s):  
3D Printing ◽  
Mechanical Performance ◽  
Matrix Material ◽  
Mechanical Analysis ◽  
Cellulose Nanofiber ◽  
Fused Filament Fabrication ◽  
Melt Mixing ◽  
The Matrix ◽  
3D Printed ◽  
Printing Parameters

In this study, nanocomposites were fabricated with polycarbonate (PC) as the matrix material. Cellulose Nanofiber (CNF) at low filler loadings (0.5 wt.% and 1.0 wt.%) was used as the filler. Samples were produced using melt mixing extrusion with the Fused Filament Fabrication (FFF) process. The optimum 3D-printing parameters were experimentally determined and the required specimens for each tested material were manufactured using FFF 3D printing. Tests conducted for mechanical performance were tensile, flexural, impact, and Dynamic Mechanical Analysis (DMA) tests, while images of the side and the fracture area of the specimens were acquired using Scanning Electron Microscopy (SEM), aiming to determine the morphology of the specimens and the fracture mechanism. It was concluded that the filler’s ratio addition of 0.5 wt.% created the optimum performance when compared to pure PC and PC CNF 1.0 wt.% nanocomposite material.

Study of the annealing influence on the mechanical performance of PA12 and PA12 fibre reinforced FFF printed specimens

2020 ◽  
Vol 26 (10) ◽  
pp. 1761-1770
Author(s):  
Isaac Ferreira ◽  
Carolina Melo ◽  
Rui Neto ◽  
Margarida Machado ◽  
Jorge Lino Alves ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Mechanical Performance ◽  
Flexural Modulus ◽  
Tensile Modulus ◽  
Annealing Treatment ◽  
Degree Of Crystallinity ◽  
Fibre Reinforcement ◽  
Scanning Calorimetry ◽  
Content Type ◽  
The Degree Of Crystallinity

Purpose The purpose of this study is to evaluate and compare the mechanical performance of FFF parts when subjected to post processing thermal treatment. Therefore, a study of the annealing treatment influence on the mechanical properties was performed. For this, two different types of Nylon (PA12) were used, FX256 and CF15, being the second a short fibre reinforcement version of the first one. Design/methodology/approach In this study, tensile and flexural properties of specimens produced via FFF were determined after being annealed at temperatures of 135°C, 150°C or 165°C during 3, 6, 12 or 18 h and compared with the non-treated conditions. Differential scanning calorimetry (DSC) was performed to determine the degree of crystallinity. To evaluate the annealing parameters’ influence on the mechanical properties, a full factorial design of experiments was developed, followed by an analysis of variance, as well as post hoc comparisons, to determine the most significative intervening factors and their effect on the results. Findings The results indicate that CF15 increased its tensile modulus, strength, flexural modulus and flexural strength around 11%, while FX256 presented similar values for tensile properties, doubling for flexural results. Flexural strain presented an improvement, indicating an increased interlayer behaviour. Concerning to the DSC analysis, an increase in the degree of crystallinity for all the annealed parts. Originality/value Overall, the annealing treatment process cause a significant improvement in the mechanical performance of the material, with the exception of 165°C annealed specimens, in which a decrease of the mechanical properties was observed, resultant of material degradation.

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