3D printed continuous carbon fiber reinforced thermoplastic composite sandwich structure with corrugated core for high stiffness/load capability

Um, Hui-Jin; Lee, Jiseok; Shin, Ji-Hwan; Kim, Kwang Ho

doi:10.1016/j.compstruct.2022.115590

Cited by 33 publications

(10 citation statements)

References 33 publications

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“…However, these traditional manufacturing processes have the defects of complicated processing, long production cycles, and high cost. In contrast, 3D printing is an advanced additive manufacturing technology that enables the rapid manufacture of complex structural parts, making it possible to achieve the integrated manufacturing of high-performance composite materials [ 8 , 9 , 10 , 11 , 12 , 13 , 14 , 15 ]. According to the pretreatment method of continuous fibers, there are two basic strategies for the 3D printing of CFTPCs: in situ impregnation and pre-impregnation methods.…”

Section: Introductionmentioning

confidence: 99%

Two-Step Preparation of CCF/PEEK Wrapped Yarn for 3D Printing Composites with Enhanced Mechanical Properties

et al. 2023

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Continuous fiber reinforced thermoplastic composites (CFTPCs) have shown advantages such as high strength, long life, corrosion resistance, and green recyclability. Three-dimensional printing of CFTPCs opened up a new strategy for the fabrication of composites with complicated structures, low cost, and short production cycles. However, a traditional 3D printing process usually causes poor impregnation of the fiber or surface damage of the fiber due to the short impregnation time or high viscosity of the thermoplastic resin. Here, continuous carbon fiber/poly(ether-ether-ketones) (CCF/PEEK) wrapped yarn was fabricated via powder impregnation and using double spinning technology for the 3D printing. The concentration of PEEK powder suspension and wire speed were optimized as 15% and 2.0 m/min. The twist of wrapped yarn was optimized as 1037 T/m. Mechanical testing showed that the 3D-printed composite wire had excellent tensile and bending strength, which was about 1.6~4.2 times larger than those without the powder pre-impregnation process. It is mainly attributed to the improved impregnation of the CF which took place during the powder pre-impregnation process. We believe that our research on wrapped yarn for 3D-printed composites provides an effective strategy for the 3D printing of composites with enhanced mechanical properties.

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Section: Introductionmentioning

confidence: 99%

Two-Step Preparation of CCF/PEEK Wrapped Yarn for 3D Printing Composites with Enhanced Mechanical Properties

et al. 2023

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“…Nowadays, polymers with sandwich structures can be prepared via several technologies, such as 3D printing, multilayer coextrusion, and injection molding foaming. − For example, the carbon fiber-reinforced thermoplastic composite with a sandwich structure was prepared via 3D printing, and its specific bending stiffness was significantly improved . Peng et al prepared LDPE/POE sandwich structure films via the coextrusion process and investigated their transparency, which showed a wide range of reversibly switchable transparency and rapidly responded to varied temperatures .…”

Section: Introductionmentioning

confidence: 99%

“…14−16 For example, the carbon fiber-reinforced thermoplastic composite with a sandwich structure was prepared via 3D printing, and its specific bending stiffness was significantly improved. 17 Peng et al prepared LDPE/POE sandwich structure films via the coextrusion process and investigated their transparency, which showed a wide range of reversibly switchable transparency and rapidly responded to varied temperatures. 18 However, there are some spaces for improvement in the above process, such as easier operation processes, shorter production cycles, and simpler equipment.…”

Section: Introductionmentioning

confidence: 99%

Mechanically Robust Foamed Polypropylene/Bamboo Powder Composite Basketworks by CO₂ Extrusion Foaming

Huang

Chong

et al. 2023

ACS Appl. Polym. Mater.

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Porous weave composites are some of the most important materials in our daily life because of their lightweight, high formability, sound and thermal insulation performance, etc. Unfortunately, the introduction of cellular structures will inevitably sacrifice the mechanical properties of porous materials. Here, we proposed a facile method to prepare mechanically robust foamed polypropylene (PP)/bamboo powder (BP) composite basketworks with sandwich structures (like cellular–solid–cellular structures) by extruding–foaming–weaving procedures. Here, the cellular structures on both sides provided weight reduction, softness, and heat insulation, while the solid part in the center improved the modulus and stiffness of the materials. Also, the evolution mechanism of the sandwich structures was revealed. Moreover, the relationship among the microstructure, thermal insulation, and mechanical thermal properties of the foamed basketworks was studied. For example, the elongation at break and specific modulus can increase from 23.6% and 124 MPa·cm3/g for PP/BP 1 to 53.3% and 350 MPa·cm3/g for PP/BP 4, respectively. Sandwich structures also provide much better thermal insulation than solid structures. Furthermore, the foamed fabrics with different colors were woven into basketworks, which can be used in placemats, decorative belts, baskets, and other fields.

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“…The results show that 3D printing technology has great application potential in the flexible design of core shapes that meet the required strength and stiffness. To date, continuous fiber reinforced composites sandwich structures, [41][42][43][44] grid structures, [45][46][47] and re-entrant type NPRSs [48][49][50] have been prepared by 3D printing technology. The key to preparing these structures is the planning of printing path.…”

Section: Introductionmentioning

confidence: 99%

Effect of printing path on compressive properties of 3D printed continuous fiber composite negative Poisson's ratio structure

et al. 2023

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In this work, continuous fiber reinforced thermoplastic negative Poisson's ratio structures (CFNPRSs) with rotating squares are fabricated by 3D printing based on a symmetrical orthogonal and one‐stoke path planning method. The influences of the printing path on the Poisson's ratio, elastic modulus and energy absorption of the structures under compression are systematically researched. The distribution of continuous fiber at the hinge has a great influence on the compression behavior of the structures. As the number of cross laps of continuous fibers at the hinge increases, the negative Poisson's ratio effect decreases while the elastic modulus and energy absorption increase. The printed CFNPRSs with no cross lap have the most obvious negative Poisson's ratio effect, with an average Poisson's ratio of −0.61. A comparative study on Poisson's ratio of the 3D printed polylactic acid negative Poisson's ratio structures (PANPRSs) is carried out, and the results show that the PANPRSs cannot achieve the negative Poisson's ratio effect because the insufficient stiffness of the printed rotation units violates the rigid assumption in theoretical model. Furthermore, the printed CFNPRSs with a lower relative density of 0.18 has an even better negative Poisson's ratio effect than the existing fiber‐reinforced auxetic structures fabricated by 3D printing. This work can provide a significant reference for the preparation of lightweight functional structures using 3D printing.Highlights The CFNPRSs with rotating squares are prepared by 3D printing technique. The path planning of the fiber at the hinge affects the properties of CFNPRSs. The negative Poisson's ratio of CFNPRSs is more obvious than that of PANPRSs. The relative density and Poisson's ratio of CFNPRSs have obvious advantages.

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3D printed continuous carbon fiber reinforced thermoplastic composite sandwich structure with corrugated core for high stiffness/load capability

Cited by 33 publications

References 33 publications

Two-Step Preparation of CCF/PEEK Wrapped Yarn for 3D Printing Composites with Enhanced Mechanical Properties

Two-Step Preparation of CCF/PEEK Wrapped Yarn for 3D Printing Composites with Enhanced Mechanical Properties

Mechanically Robust Foamed Polypropylene/Bamboo Powder Composite Basketworks by CO₂ Extrusion Foaming

Effect of printing path on compressive properties of 3D printed continuous fiber composite negative Poisson's ratio structure

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3D printed continuous carbon fiber reinforced thermoplastic composite sandwich structure with corrugated core for high stiffness/load capability

Cited by 33 publications

References 33 publications

Two-Step Preparation of CCF/PEEK Wrapped Yarn for 3D Printing Composites with Enhanced Mechanical Properties

Two-Step Preparation of CCF/PEEK Wrapped Yarn for 3D Printing Composites with Enhanced Mechanical Properties

Mechanically Robust Foamed Polypropylene/Bamboo Powder Composite Basketworks by CO2 Extrusion Foaming

Effect of printing path on compressive properties of 3D printed continuous fiber composite negative Poisson's ratio structure

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Mechanically Robust Foamed Polypropylene/Bamboo Powder Composite Basketworks by CO₂ Extrusion Foaming