Query: continuous fiber reinforced composite   3d printing

title: Fatigue behaviors of fiber reinforced composite 3D printing
abstract: This chapter presents the current scientific studies on fatigue properties of continuous fiber reinforced additive manufacturing (FRAM) The conducted research studies have focused on the effect of fiber orientation and fiber volume fraction to the cyclic load life of components. Specimens were tested at load ratios of R 0 and R 0.1. The materials tested were fiberglass, carbon fiber, and Kevlar. 0 degree fiber orientation specimens showed the highest endurance. Among materials, carbon fiber reinforced specimens performed the best. One of the studies conducted analysis of variance (ANOVA) to understand the effect of different parameters. Since fiber orientation and fiber volume fraction can be adjusted for each layer, the mechanical properties are also changed. Understanding the effect of these parameters to the fatigue properties can be crucial in design of parts and failure preventing.

title: Fiber Traction Printing: A 3D Printing Method of Continuous Fiber Reinforced Metal Matrix Composite
abstract: A novel metal matrix composite freeform fabrication approach, fiber traction printing (FTP) is demonstrated through controlling the wetting behavior between fibers and the matrix. This process utilizes the fiber bundle to control the cross sectional shape of the liquid metal, shaping it from circular to rectangular which is more precise. The FTP process could resolve manufacturing difficulties in the complex structure of continuous fiber reinforced metal matrix composites. The printing of the first layer monofilament is discussed in detail, and the effects of the fibrous coating thickness on the mechanical properties and microstructures of the composite are also investigated in this paper. The composite material prepared by the FTP process has a tensile strength of 235.2 MPa, which is close to that of composites fabricated by conventional processes. The complex structures are printed to demonstrate the advantages and innovations of this approach. Moreover, the FTP method is suited to other material systems with good wettability, such as modified carbon fiber, surfactants, and aluminum alloys.

title: Determining process window for manufacturing of continuous carbon fiber reinforced composite Using 3D printing
abstract: Continuous carbon fiber reinforced acrylonitrile butadiene styrene (ABS) has been manufactured by a method based on fused deposition modeling (FDM) Before 3D printing, the carbon fibers pass through an ABS acetone bath to prepare solution impregnated fibers (prepregs) Continuous fiber reinforced thermoplastic composites (CFRTCs) were printed by feeding carbon fiber prepregs and ABS filament, simultaneously into a special single port nozzle. By varying print conditions such as nozzle diameter, layer height, and print speed, composite specimens were printed with different qualities. The visual evaluation of printed composites was used to determine a process window for stable or unstable CFRTC printing. In the obtained process window, four regions were observed including fiber fuzzing or tearing instability, fiber twisting instability, low quality stable print and high quality stable print. The optimum condition to print CFRTCs was found and then specimens were printed to investigate mechanical properties under the optimal printing condition. The mechanical and morphological properties of visual optimized 3D printed composites, without any fiber fuzzing, tearing or twisting were investigated. The results showed that tensile, flexural, and interlaminar shear strength of 3D printed ABS carbon CFRTCs have increased 313% 121% and 54% respectively, when compared with the neat ABS 3D printed samples.

title: 3D Printing Method of Spatial Curved Surface by Continuous Natural Fiber Reinforced Composite

title: A constitutive model for 3D printed continuous fiber reinforced composite structures with variable fiber content
abstract: 3D printing provides a new technical means for the preparation of functionally controlled continuous fiber reinforced composites (CFRCs) with variable fiber content. The constitutive model of 3D printed CFRCs with different fiber contents are the basis for establishing mechanical analysis models and design methods of functionally regulated CFRCs based on 3D printing. In this paper, stiffness and strength properties of 3D printed CFRCs with different fiber contents were systematically studied, and the mapping relationship between material properties and fiber content was obtained. The failure processes of 3D printed CFRCs under different loads were studied by microstructural morphology and interfacial performance analysis, revealing the formation mechanisms of the material properties. The constitutive model and finite element analysis method of 3D printed CFRCs were established by using the material properties of 3D printed CFRCs with different fiber contents. The mechanical analysis mode was used to predict and analyze the performance of functionally graded CFRCs with variable fiber content. The results show that the mechanical analysis mode can be used for the optimization design and mechanical analysis of functionally controlled CFRCs.

title: 3D Printing of Continuous Fiber Reinforced Low Melting Point Alloy Matrix Composites: Mechanical Properties and Microstructures
abstract: A novel 3D printing route to fabricate continuous fiber reinforced metal matrix composite (CFRMMC) is proposed in this paper. It is distinguished from the 3D printing process of polymer matrix composite that utilizes the pressure inside the nozzle to combine the matrix with the fiber. This process combines the metallic matrix with the continuous fiber by utilizing the wetting and wicking performances of raw materials to form the compact internal structures and proper fiber matrix interfaces. CF/Pb50Sn50 composites were printed with the Pb50Sn50 alloy wire and modified continuous carbon fiber. The mechanical properties of the composite specimens were studied, and the ultimate tensile strength reached 236.7 MPa, which was 7.1 times that of Pb50Sn50 alloy. The fracture and interfacial microstructure were investigated and analyzed. The relationships between mechanical properties and interfacial reactions were discussed. With the optimized process parameters, several composites parts were printed to demonstrate the advantages of low cost, short fabrication period and flexibility in fabrication of complex structures.

title: Effect of Process Parameters on Tensile Mechanical Properties of 3D Printing Continuous Carbon Fiber Reinforced PLA Composites
abstract: Three dimensional (3D) printing continuous carbon fiber reinforced polylactic acid (PLA) composites offer excellent tensile mechanical properties. The present study aimed to research the effect of process parameters on the tensile mechanical properties of 3D printing composite specimens through a series of mechanical experiments. The main printing parameters, including layer height, extrusion width, printing temperature, and printing speed are changed to manufacture specimens based on the modified fused filament fabrication 3D printer, and the tensile mechanical properties of 3D printing continuous carbon fiber reinforced PLA composites are presented. By comparing the outcomes of experiments, the results show that relative fiber content has a significant impact on mechanical properties and the ratio of carbon fibers in composites is influenced by layer height and extrusion width. The tensile mechanical properties of continuous carbon fiber reinforced composites gradually decrease with an increase of layer height and extrusion width. In addition, printing temperature and speed also affect the fiber matrix interface, i.e. tensile mechanical properties increase as the printing temperature rises, while the tensile mechanical properties decrease when the printing speed increases. Furthermore, the strengthening mechanism on the tensile mechanical properties is that external loads subjected to the components can be transferred to the carbon fibers through the fiber matrix interface. Additionally, SEM images suggest that the main weakness of continuous carbon fiber reinforced 3D printing composites exists in the fiber matrix interface, and the main failure is the pull out of the fiber caused by the interface destruction.

title: Mechanical characterization of FDM 3D printing of continuous carbon fiber reinforced PLA composites
abstract: Additive manufacturing of fiber reinforced composites is of great interest in various industrial applications. In this study, an innovative extruder is designed and manufactured for fused deposition modeling (FDM) 3D printers in order to produce continuous fiber reinforced thermoplastic (CFRT) composites. There are some challenges along this way such as making tension in fiber, fiber surface preparation, printing temperature and feed rate to produce a composite part with good quality. These challenges are discussed in detail. The main advantage of this extruder is that it can be mounted on the available FDM 3D printers and consequently there is no need to design a new chassis. In order to assess the quality of products, standard tensile and three point bending specimens made of pure poly lactic acid (PLA) and carbon fiber reinforced PLA are printed and tested under quasi static loading. Experimental results show significant improvements of tensile and bending properties of PLA. Morphological analysis is also conducted to study the bonding between the carbon fiber and PLA.

title: Ultrasound assisted 3D printing of continuous fiber reinforced thermoplastic (FRTP) composites
abstract: Investigation of manufacturing continuous fiber reinforced thermoplastic polymer composites (CFRTPCs) through 3D printing technologies has attracted great attention in the past few years due to excellent properties of CFRTPCs, such as high strength to weight ratio and stiffness. It is found that the properties of CFRTPCs are affected not only by the properties of the individual parent materials but also by interfacial characteristics. Modification of the interface is a great method to improve the wettability between fiber and polymer and hence the mechanical properties of CFRTPCs. In this work, an ultrasound assisted 3D printing device for CFRTPCs is developed. The changes of surface profile and chemical structure of carbon fiber and carbon fiber prepreg after ultrasonic treatment are studied. The effects of ultrasonic processing parameters on the microstructure and mechanical properties of CFRTPCs are provided. It is found that the tensile and flexural strength of composite materials are improved by 34% and 29% respectively, compared with untreated material by using the ultrasonic amplitude of 40 mm, resin solution mass fraction of 10% processing speed of 15 mm/s.

title: An Overview of Research on FDM 3D Printing Process of Continuous Fiber Reinforced Composites
abstract: Continuous fiber reinforced composites have excellent mechanical properties, but traditional processes are costly, complex to form, have a long production cycle, and are only suitable for relatively simple structures, which limits the wider application of the material. Fuse Deposition Modeling(FDM) 3D printing has the advantages of simple process, fast molding, low cost, and the ability to manufacture high complexity structures, which provides the possibility of low cost and rapid prototyping of composite materials. In this paper, several FDM 3D printing processes for continuous fiber composites are reviewed, and the effects of some related process parameters on the properties of the composites are analyzed. Finally, the problems of FDM 3D printing continuous fiber reinforced composites are pointed out.