We have developed a method for the three-dimensional (3D) printing of continuous fiber-reinforced thermoplastics based on fused-deposition modeling. The technique enables direct 3D fabrication without the use of molds and may become the standard next-generation composite fabrication methodology. A thermoplastic filament and continuous fibers were separately supplied to the 3D printer and the fibers were impregnated with the filament within the heated nozzle of the printer immediately before printing. Polylactic acid was used as the matrix while carbon fibers, or twisted yarns of natural jute fibers, were used as the reinforcements. The thermoplastics reinforced with unidirectional jute fibers were examples of plant-sourced composites; those reinforced with unidirectional carbon fiber showed mechanical properties superior to those of both the jute-reinforced and unreinforced thermoplastics. Continuous fiber reinforcement improved the tensile strength of the printed composites relative to the values shown by conventional 3D-printed polymer-based composites.

A study was conducted to evaluate the current production capabilities of the Mark One ® 3D printer in printing carbon fibre reinforced thermoplastic (CFRTP) tensile test specimens according to the JIS K 7073 by making use of fused deposition modelling. Several different types of CFRTP tensile test specimens are printed and are tensile tested in the longitudinal direction to obtain an overview of the mechanical properties of 3D printed CFRTP material. These properties are compared with the literature values known for composite materials to see if these agree. The main goal of this research is to increase the knowledge of the 3D printing process of CFRTP and to later use this knowledge to further improve the 3D printing process to obtain stronger 3D printed CFRTP materials.

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Carbon Fiber Reinforced Plastic (CFRP) is composed of electric conductive carbon fibers and electric insulator resin. Self-monitoring system has been reported utilizing electric resistance change of unidirectional CFRP due to fiber breakages and to applied strain. Piezoresistivity is electric resistance change with applied strain. Many researchers have already reported the piezoresistivity of unidirectional CFRP. There is, however, large discrepancy in the measured piezoresistivity even in the fiber direction during tensile loading: both positive piezoresistivity (electric resistance increase) and negative piezoresistivity (electric resistance decrease) are reported during tensile tests. Electric resistance change at electrodes due to poor electric contacts are reported to be a main cause of this large discrepancy. In the present study, therefore, basic properties of piezoresistivity were measured with specimens made from single-ply and multi-ply laminates using a four-prove method. Many cases of electric resistance changes in the fiber direction transverse direction were measured during tensile loading. Effect of shear loading was also investigated using a shear test. To investigate the effect of poor electric contact at the electrodes, electrodes were made without polishing specimen surface and a tensile test was performed with measuring piezoresistivity. After the test, the specimen surface was polished, and a tensile test was performed again using the identical specimen. As a result, positive piezoresistivity was obtained for both single-ply and multi-ply specimens and negative piezoresistivity is confirmed that it was caused by the poor electric contact at electrodes.

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