High-performance curved sections in 3D printed continuous carbon fibre reinforced thermoplastic composites using aligned fibre deposition
Source abstract
Abstract
This paper presents high-performance curved sections in 3D printed continuous carbon fibre reinforced thermoplastic composites using an aligned fibre deposition (AFD) method on a 6-axis robotic arm. 3D printed curved composite beams using both AFD and conventional methods are mechanically tested under four-point bending and scanned by X-ray computed microtomography (μCT) to characterise the fibre distribution and develop image-based finite element models. Compared to conventional printing method using a commercial nozzle, the proposed AFD method significantly improves the fibre alignment and reduces void content in the printed composites, and the curved beam strength is calculated as 204.2 N and 224.5 N for the cases of 7 mm and 15 mm radius of curvature, achieving an improvement of 34.0% and 45.3%, respectively. The modelling produces excellently matched stiffness with the experimental measurement, providing useful insights into the stress and strain distributions. The combination of experimental data and modelling results shows that the alignment of fibres in the curved composite beams plays a key role in improving mechanical performance and determining the final failure mode.
Source: openalex_inverted_index · Quality: baseline
Research context
OpenAlex topics: Additive Manufacturing and 3D Printing Technologies · Composite Material Mechanics · Mechanical Behavior of Composites
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (43)
Show source-provided references
1. A critical review on 3D printed continuous fiber-reinforced composites: history, mechanism, materials and properties10.1016/j.compstruct.2019.111476 ↗
2. A critical review on the fused deposition modeling of thermoplastic polymer composites10.1016/j.compositesb.2020.108336 ↗
3. Additively manufactured carbon fiber-reinforced composites: state of the art and perspective
4. Three-dimensional printing of continuous-fiber composites by in-nozzle impregnation10.1038/srep23058 ↗
5. Fabrication of continuous carbon, glass and Kevlar fibre reinforced polymer composites using additive manufacturing
6. Material extrusion additive manufacturing of continuous fibre reinforced polymer matrix composites: a review and outlook10.1016/j.compositesb.2021.109143 ↗
7. Multi-axis additive manufacturing process for continuous fibre reinforced composite parts10.1016/j.procir.2019.09.022 ↗
8. Effects of set curvature and fiber bundle size on the printed radius of curvature by a continuous carbon fiber composite 3D printer
9. Compressive strength degradation of the curved sections of 3D-printed continuous carbon fiber composite10.1016/j.compositesa.2020.106244 ↗
10. Testing method for evaluating mechanical properties of 3D printed CFRP with curved fibers by four-point bending test of L-shaped specimen
11. A study of the influence of processing parameters on steering of carbon Fibre/PEEK tapes using laser-assisted tape placement10.1016/j.compositesb.2018.11.033 ↗
12. The engineering aspects of automated prepreg layup: history, present and future10.1016/j.compositesb.2011.12.003 ↗
13. Stiffness-based optimization framework for the topology and fiber paths of continuous fiber composites10.1016/j.compositesb.2019.107681 ↗
14. Field-based toolpath generation for 3D printing continuous fibre reinforced thermoplastic composites
15. Fibre misalignment and breakage in 3D printing of continuous carbon fibre reinforced thermoplastic composites
16. An investigation into 3D printing of fibre reinforced thermoplastic composites
17. Carbon fibre damage during 3d printing of polymer matrix laminates using the fdm process
18. Improved fibre placement in filament-based 3D printing of continuous carbon fibre reinforced thermoplastic composites10.1016/j.compositesa.2023.107454 ↗
19. Mechanism of folding a fiber bundle in the curved section of 3D printed carbon fiber reinforced plastics10.1080/09243046.2019.1682794 ↗
20. Consolidation of continuous fibre reinforced composites in additive processes: a review
21. Fiber orientation measurements in composite materials10.1016/j.compositesa.2005.04.021 ↗
22. Advances in hybrid fibers reinforced polymer-based composites prepared by FDM: a review on mechanical properties and prospects10.1016/j.coco.2023.101592 ↗
23. Investigation of a new approach for additively manufactured continuous fiber-reinforced polymers10.1016/j.procir.2017.03.276 ↗
24. 3D compaction printing of a continuous carbon fiber reinforced thermoplastic10.1016/j.compositesa.2020.105985 ↗
25. Hygromechanical properties of 3D printed continuous carbon and glass fibre reinforced polyamide composite for outdoor structural applications
26. Characterising microstructural organisation in unidirectional composites10.1016/j.compscitech.2021.109030 ↗
27. Individual fibre segmentation from 3D X-ray computed tomography for characterising the fibre orientation in unidirectional composite materials10.1016/j.compositesa.2016.12.028 ↗
28. Evolution of fibre deflection leading to kink-band formation in unidirectional glass fibre/epoxy composite under axial compression10.1016/j.compscitech.2021.108929 ↗
29. Smith · 2009
30. Development of RVE-embedded solid elements model for predicting effective elastic constants of discontinuous fiber reinforced composites10.1016/j.mechmat.2015.10.011 ↗
31. A combined use of embedded and cohesive elements to model damage development in fibrous composites10.1016/j.compstruct.2019.110921 ↗
32. Finite element modelling of 3D printed continuous carbon fiber composites: embedded elements technique and experimental validation10.1016/j.compstruct.2022.115631 ↗
33. Development of a procedure to model the mechanical behavior of composites with embedded element method by considering the matrix non-linearity10.1016/j.compstruct.2020.113400 ↗
34. The interplay between multiple toughening mechanisms in nanocomposites with spatially distributed and oriented carbon nanotubes as revealed by dual-scale simulations10.1016/j.carbon.2018.10.005 ↗
35. Influence of fibre misalignment and voids on composite laminate strength10.1177/0021998314557533 ↗
36. Compressive failure of UD-CFRP containing void defects: in situ SEM microanalysis10.1016/j.compscitech.2011.04.009 ↗
37. 3D printed continuous CF/PA6 composites: effect of microscopic voids on mechanical performance10.1016/j.compscitech.2020.108077 ↗
38. Influence of voids on the compressive failure behaviour of fibre-reinforced composites10.1016/j.compscitech.2015.06.020 ↗
39. Failure analysis of unidirectional CFRP composites with the coupled effects of initial fibre waviness and voids under longitudinal compression10.1016/j.compstruct.2024.118451 ↗
40. Composite laminate failure analysis using multicontinuum theory10.1016/S0266-3538(03)00219-7 ↗
41. Standard Test Method for Measuring the Curved Beam Strength of a Fiber-Reinforced Polymer-Matrix Composite.
42. 2012
43. A finite fracture mechanics formulation to predict fibre kinking and splitting in CFRP under combined longitudinal compression and in-plane shear10.1016/j.mechmat.2011.08.002 ↗