scholarly journals 3D printing of Continuous Fiber Reinforced Composites: A Review of the Processing, Pre- and Post-Processing Effects on Mechanical Properties

2021 ◽  
Author(s):  
Faraz Safari ◽  
Abdolvahed Kami ◽  
Vahid Abedini
Keyword(s):  
Mechanical Properties ◽  
3D Printing ◽  
Fused Deposition Modeling ◽  
Fiber Reinforced Composites ◽  
Reinforced Composites ◽  
Fiber Reinforced ◽  
Post Processing ◽  
Continuous Fiber ◽  
Fused Deposition ◽  
Production Techniques

The main objective of this study is to review existing research on the application of fused deposition modeling (FDM) for 3D printing of continuous fiber reinforced composites (CFRCs). An overview of additive manufacturing (AM) technology production techniques is provided first, followed by a look into FDM technology. The articles on CFRC printing were then summarized. The type of reinforcing material and matrix utilized, the research subject, the mechanical properties investigated, and the sample dimensions are all listed. Various pre-processing, processing, and post-processing conditions, as well as their impact on CFRC mechanical properties, were also discussed.

scholarly journals The Micro–Macro Interlaminar Properties of Continuous Carbon Fiber-Reinforced Polyphenylene Sulfide Laminates Made by Thermocompression to Simulate the Consolidation Process in FDM

Polymers ◽  
2022 ◽  
Vol 14 (2) ◽  
pp. 301
Author(s):  
Jiale Hu ◽  
Suhail Mubarak ◽  
Kunrong Li ◽  
Xu Huang ◽  
Weidong Huang ◽  
...  
Keyword(s):  
Carbon Fiber ◽  
3D Printing ◽  
Manufacturing Industry ◽  
Fused Deposition Modeling ◽  
Polyphenylene Sulfide ◽  
Fiber Reinforced ◽  
Continuous Fiber ◽  
Fused Deposition ◽  
Continuous Carbon Fiber ◽  
Carbon Fiber Reinforced

Three-dimensional (3D) printing of continuous fiber-reinforced composites has been developed in recent decades as an alternative means to handle complex structures with excellent design flexibility and without mold forming. Although 3D printing has been increasingly used in the manufacturing industry, there is still room for the development of theories about how the process parameters affect microstructural properties to meet the mechanical requirements of the printed parts. In this paper, we investigated continuous carbon fiber-reinforced polyphenylene sulfide (CCF/PPS) as feedstock for fused deposition modeling (FDM) simulated by thermocompression. This study revealed that the samples manufactured using a layer-by-layer process have a high tensile strength up to 2041.29 MPa, which is improved by 68.8% compared with those prepared by the once-stacked method. Moreover, the mechanical–microstructure characterization relationships indicated that the compactness of the laminates is higher when the stacked CCF/PPS are separated, which can be explained based on both the void formation and the nanoindentation results. These reinforcements confirm the potential of remodeling the layer-up methods for the development of high-performance carbon fiber-reinforced thermoplastics. This study is of great significance to the improvement of the FDM process and opens broad prospects for the aerospace industry and continuous fiber-reinforced polymer matrix materials.

Future requirements in the characterization of continuous fiber-reinforced polymeric composites (IUPAC Technical Report)

2002 ◽  
Vol 74 (4) ◽  
pp. 601-628 ◽  
Author(s):  
D. R. Moore ◽  
A. J. Cervenka
Keyword(s):  
Mechanical Properties ◽  
Fiber Reinforced Composites ◽  
Reinforced Composites ◽  
Fiber Reinforced ◽  
Continuous Fiber ◽  
Interfacial Effects ◽  
Technical Report ◽  
Processing Properties ◽  
Historic Background

Characterization of continuous fiber-reinforced composites is examined in terms of processing, properties, and structure. Five processing and five property topics are then examined in terms of reviewing some of the historic background in these areas with the aim of identifying current issues and requirements for the future. The topics covered in the processing section are: polymeric matrix, impregnation, interfacial effects, residual stresses, and pre-preg tack. In the mechanical properties section the topics are: choice of standard, recycling and reusability, durability, environmental strength, and toughness. The paper provides a ten-point plan for future requirements.

Improving mechanical properties of continuous fiber-reinforced thermoplastic composites produced by FDM 3D printer

2018 ◽  
Vol 38 (3) ◽  
pp. 99-116 ◽  
Author(s):  
Behnam Akhoundi ◽  
Amir Hossein Behravesh ◽  
Arvin Bagheri Saed
Keyword(s):  
Mechanical Properties ◽  
Fused Deposition Modeling ◽  
Thermoplastic Composites ◽  
3D Printer ◽  
Fiber Reinforced ◽  
Continuous Fiber ◽  
Fiber Volume ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Consistent Method

The main purpose of this research is to bolster mechanical properties of the parts, produced by an extrusion-based 3D printer, or fused deposition modeling machine, via increasing the content of continuous fiber yarn to its practical limit. In-melt continuous glass fiber yarn embedding was applied as a reliable and consistent method for simultaneous impregnation to produce continuous fiber-reinforced thermoplastic composites in the fused deposition modeling process. It is well known that the main weakness in the fused deposition modeling 3D printed products is their low strength compared to the manufactured ones by conventional methods such as injection molding and machining processes. This characteristic can be related to both inherent weakness of thermoplastic materials and poor adhesion between the deposited rasters and the layers. Although various attempts have been performed to tackle this issue, it is widely believed that using continuous fibers is the most effective method to serve this purpose if a reliable and consistent method is implemented. Since the mechanical properties of continuous fiber-reinforced composites directly depend on the content of fiber volume, maximizing the fiber content as well as producing an integrated part was assumed as the main objective. In this work, an analysis of various patterns of raster deposition was conducted, followed by the experiments and verification. The effective parameters on the fiber yarn volume, such as fiber yarn diameter, fiber yarn laying pattern, extrusion width, layer height, and flow percentage, were investigated and their optimal values were reported. The attained experimental results showed that, for polylactic acid-glass fiber yarn reinforced composite, with the extrusion width of 0.3 mm, the layer heights of 0.22 mm, flow percentage of 0.43, and the rectangular laying pattern, approximately 50% fiber-volume content can be achieved which resulted in tensile yield strength and modulus of 478 MPa and 29.4 GPa, respectively. There was an excellent agreement between these experimental results and predicted theoretically values by rule of mixture.

scholarly journals 3D Printing of Fiber-Reinforced Plastic Composites Using Fused Deposition Modeling: A Status Review

Materials ◽  
2021 ◽  
Vol 14 (16) ◽  
pp. 4520
Author(s):  
Salman Pervaiz ◽  
Taimur Ali Qureshi ◽  
Ghanim Kashwani ◽  
Sathish Kannan
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
3D Printing ◽  
Fused Deposition Modeling ◽  
Fiber Reinforced Polymers ◽  
Fiber Reinforced ◽  
Reinforced Polymers ◽  
Fused Deposition ◽  
Frp Composites ◽  
Deposition Modeling

Composite materials are a combination of two or more types of materials used to enhance the mechanical and structural properties of engineering products. When fibers are mixed in the polymeric matrix, the composite material is known as fiber-reinforced polymer (FRP). FRP materials are widely used in structural applications related to defense, automotive, aerospace, and sports-based industries. These materials are used in producing lightweight components with high tensile strength and rigidity. The fiber component in fiber-reinforced polymers provides the desired strength-to-weight ratio; however, the polymer portion costs less, and the process of making the matrix is quite straightforward. There is a high demand in industrial sectors, such as defense and military, aerospace, automotive, biomedical and sports, to manufacture these fiber-reinforced polymers using 3D printing and additive manufacturing technologies. FRP composites are used in diversified applications such as military vehicles, shelters, war fighting safety equipment, fighter aircrafts, naval ships, and submarine structures. Techniques to fabricate composite materials, degrade the weight-to-strength ratio and the tensile strength of the components, and they can play a critical role towards the service life of the components. Fused deposition modeling (FDM) is a technique for 3D printing that allows layered fabrication of parts using thermoplastic composites. Complex shape and geometry with enhanced mechanical properties can be obtained using this technique. This paper highlights the limitations in the development of FRPs and challenges associated with their mechanical properties. The future prospects of carbon fiber (CF) and polymeric matrixes are also mentioned in this study. The study also highlights different areas requiring further investigation in FDM-assisted 3D printing. The available literature on FRP composites is focused only on describing the properties of the product and the potential applications for it. It has been observed that scientific knowledge has gaps when it comes to predicting the performance of FRP composite parts fabricated under 3D printing (FDM) techniques. The mechanical properties of 3D-printed FRPs were studied so that a correlation between the 3D printing method could be established. This review paper will be helpful for researchers, scientists, manufacturers, etc., working in the area of FDM-assisted 3D printing of FRPs.

Process parameters and mechanical properties of continuous glass fiber reinforced composites-polylactic acid by fused deposition modeling

2021 ◽  
pp. 073168442199801
Author(s):  
Yesong Wang ◽  
Dekun Kong ◽  
Qing Zhang ◽  
Wei Li ◽  
Jiang Liu
Keyword(s):  
Mechanical Properties ◽  
Glass Fiber ◽  
Polylactic Acid ◽  
Fiber Reinforced Composites ◽  
Reinforced Composites ◽  
Fiber Reinforced ◽  
Continuous Glass ◽  
Fused Deposition ◽  
Continuous Glass Fiber ◽  
Glass Fiber Reinforced

This article focuses on 3D printing of continuous glass fiber reinforced composites-polylactic acid by fused deposition modeling. An innovative continuous fiber reinforced composite 3D printer and self-made continuous glass fiber reinforced filament-polylactic acid are applied to study the influences of process parameters including printing temperature, speed, layer height, and fiber volume fraction on mechanical properties of continuous glass fiber reinforced composites-polylactic acid printing samples. Tensile and three-point bending tests are carried out to explore the mechanical responses of printed samples. Experimental results show that the mechanical properties of continuous glass fiber reinforced composites-polylactic acid printing samples are better than those of polylactic acid samples. The tensile and flexural strengths of the specimens are increased by 400% and 204% when the fiber volume fractions are about 5.21% and 6.24%, respectively. The microscopic observations of the fracture surfaces of the tensile samples are also conducted to analyze the influences of layer heights on tensile strength and failure mechanism.

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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