3D printing of continuous carbon fiber reinforced polyphenylene sulfide: Exploring printability and importance of fiber volume fraction

Parker, Mallory; Inthavong, A.; Law, Esther; Waddell, Sarah; Ezeokeke, N.; Matsuzaki, Ryosuke; Arola, D.

doi:10.1016/j.addma.2022.102763

Cited by 16 publications

(5 citation statements)

References 31 publications

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“…With the development of FDM 3D printing technology, there are studies to improve its printing accuracy and dimensional stability. 56 Parker et al 57 improved the Prusa I3 MK3S, a commercial FDM 3D printer, to print continuous carbon fiber (CCF)/polyphenylene sulfide (PPS) composites more uniformly and smoothly.…”

Section: Fused Deposition Modelingmentioning

confidence: 99%

“…With the development of FDM 3D printing technology, there are studies to improve its printing accuracy and dimensional stability 56 . Parker et al 57 improved the Prusa I3 MK3S, a commercial FDM 3D printer, to print continuous carbon fiber (CCF)/polyphenylene sulfide (PPS) composites more uniformly and smoothly. Improvements included: rewiring the heater coil to the temperature controller, installing high‐temperature type K thermocouples for precise nozzle temperature control, installing a separate 24 V direct current power supply for the temperature controller, adding a cooling fan, replacing the traditional metal ridged extruder rollers with aluminum extruder feeder drives with polyurethane (PU) rollers to minimize print filament damage, and using polytetrafluoroethylene (PTFE) tubing to introduce fibers into the nozzle assembly.…”

Section: Improvements In 3d Printing Technology For Polymer Compositesmentioning

confidence: 99%

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Advances in 3D printing for polymer composites: A review

Ma,

Zhang,

Ruan

et al. 2024

InfoMat

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The potential of three‐dimensional (3D) printing technology in the fabrication of advanced polymer composites is becoming increasingly evident. This review discusses the latest research developments and applications of 3D printing in polymer composites. First, it focuses on the optimization of 3D printing technology, that is, by upgrading the equipment or components or adjusting the printing parameters, to make them more adaptable to the processing characteristics of polymer composites and to improve the comprehensive performance of the products. Second, it focuses on the 3D printable novel consumables for polymer composites, which mainly include the new printing filaments, printing inks, photosensitive resins, and printing powders, introducing the unique properties of the new consumables and different ways to apply them to 3D printing. Finally, the applications of 3D printing technology in the preparation of functional polymer composites (such as thermal conductivity, electromagnetic interference shielding, biomedicine, self‐healing, and environmental responsiveness) are explored, with a focus on the distribution of the functional fillers and the influence of the topological shapes on the properties and functional characteristics of the 3D printed products. The aim of this review is to deepen the understanding of the convergence between 3D printing technology and polymer composites and to anticipate future trends and applications.image

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Section: Fused Deposition Modelingmentioning

confidence: 99%

Section: Improvements In 3d Printing Technology For Polymer Compositesmentioning

confidence: 99%

Advances in 3D printing for polymer composites: A review

Ma,

Zhang,

Ruan

et al. 2024

InfoMat

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“…PPS has a glass transition temperature ( T g ) of 358 K (85 °C) and high melting temperature ( T m ) of ~558 K (~285 °C) [ 14 ], and can withstand higher temperatures of ~473 K (~200 °C) [ 11 ]. PPS has been used for large-scale CFRTP-PPS parts such as 3D-printed composite articles [ 16 ]; including, that of continuous CF with nominal V f of 30 to 50%, reaching ultimate tensile strength of 1930 +/− 150 MPa [ 17 ]. CFRTP-PPS is well-researched, with recent studies that include: effect of cooling rate on elastic modulus and ultimate tensile strength [ 18 ]; heat treatment process to remove CF fabric sizing on laminates showing that Charpy impact strength was more dependent on CF volume fraction [ 19 ]; and an inventory analysis on CFRTP-PPS manufacture in the aerospace industry, exemplifying the urgent need to lower environmental impact [ 20 ].…”

Section: Introductionmentioning

confidence: 99%

A New Strengthening Process for Carbon-Fiber-Reinforced Thermoplastic Polyphenylene Sulfide (CFRTP-PPS) Interlayered Composite by Electron Beam Irradiation to PPS Prior to Lamination Assembly and Hot Press

et al. 2023

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Impact by hailstone, volcanic rock, bird strike, or also dropping tools can cause damage to aircraft materials. For maximum safety, the goal is to increase Charpy impact strength (auc) of a carbon-fiber-reinforced thermoplastic polyphenylene sulfide polymer (CFRTP-PPS) composite for potential application to commercial aircraft parts. The layup was three cross-weave CF plies alternating between four PPS plies, [PPS-CF-PPS-CF-PPS-CF-PPS], designated [PPS]4[CF]3. To strengthen, a new process for CFRP-PPS was employed applying homogeneous low voltage electron beam irradiation (HLEBI) to both sides of PPS plies prior to lamination assembly with untreated CF, followed by hot press under 4.0 MPa at 573 K for 8 min. Experimental results showed a 5 kGy HLEBI dose was at or near optimum, increasing auc at each accumulative probability, Pf. Optical microscopy of 5 kGy sample showed a reduction in main crack width with significantly reduced CF separation and pull-out; while, scanning electron microscopy (SEM) and electron dispersive X-ray (EDS) mapping showed PPS adhering to CF. Electron spin resonance (ESR) of a 5 kGy sample indicated lengthening of PPS chains as evidenced by a reduction in dangling bond peak. It Is assumed that 5 kGy HLEBI creates strong bonds at the interface while strengthening the PPS bulk. A model is proposed to illustrate the possible strengthening mechanism.

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“…3D printing technology is now able to print different types of materials: polymeric materials (polyamide, acrylonitrile butadiene styrene, polylactic acid, polyurethane) (Harris et al, 2019), metals (Duda and Raghavan, 2016;Panwisawas et al, 2020), and composites (carbon, glass) (Lee et al, 2023). However, 3D printed parts, particularly the ones made of composites, have an inherent drawback, i.e., low fiber volume fraction (< 30%) (Parker et al, 2022) and high porosity/void content (Tao et al, 2021). The typical void content in 3D printed composites is approximately 12%, which is reasonably high in comparison to RTM-made or autoclave-made composites (1%-5%) (He et al, 2020).…”

Section: Introductionmentioning

confidence: 99%

Post-consolidation process for modifying microscale and mesoscale parameters of 3D printed composite materials

Yudhanto,

Aldhirgham,

Feron

et al. 2023

Front. Mater.

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Advancements in additive manufacturing technology (3D printing) have enabled us to fabricate reasonably good parts using continuous fiber-reinforced matrix composites. Unfortunately, most of these 3D-printed composite parts inherently possess a large number of voids originating from the trapped air within and between molten composite beads during the deposition stage. Removing the voids has thus become a key challenge in attempts to apply 3D printed composite parts for fabricating stiff/strong load-bearing structures. Here, we employed a classical process, viz. compression molding, to post-consolidate 3D-printed continuous carbon fiber-reinforced polyamide (CFPA), and to investigate the implications in terms of microscale parameters (void content) and mesoscale parameters (mechanical properties, plasticity, damage) using matrix-dominated lay-up of [±45]2s. We found that the proposed post-consolidation process could reduce the void of 3D-printed CFPA from 12.2% to 1.8%, enhancing the shear modulus and shear strength by 135% and 116%, respectively. The mesoscale analysis shows that, albeit with less ductility, the post-consolidated CFPA laminate was more resistant to damage than the 3D-printed CFPA. Classical compression molding is thus a promising technique for improving the physical and mechanical performances of 3D-printed composites by reducing inherent void built-ups.

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3D printing of continuous carbon fiber reinforced polyphenylene sulfide: Exploring printability and importance of fiber volume fraction

Cited by 16 publications

References 31 publications

Advances in 3D printing for polymer composites: A review

Advances in 3D printing for polymer composites: A review

A New Strengthening Process for Carbon-Fiber-Reinforced Thermoplastic Polyphenylene Sulfide (CFRTP-PPS) Interlayered Composite by Electron Beam Irradiation to PPS Prior to Lamination Assembly and Hot Press

Post-consolidation process for modifying microscale and mesoscale parameters of 3D printed composite materials

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