Abstract:The main objective of this study is to review existing research on the application of fused deposition modeling (FDM) for 3D printing of continuous fiber reinforced composites (CFRCs). An overview of additive manufacturing technology production techniques is provided first, followed by a look into FDM technology. The articles on CFRC printing were then summarized. The type of reinforcing material and matrix utilized, the studied parameters, the mechanical tests, and their results, are all listed. Various pre-p… Show more
“…Continuous fiber reinforcement is still an emerging issue for FDM printing. Nevertheless, there are some examples in the literature, 47,48 and we used them as upper threshold and for comparative analysis with the short fibers (0.08 mm and 0.1 mm). We depict 0.1 mm fiber-reinforced RVE in Figure 3, and continuous fiber reinforcement in Figure 2.Figure 2.Representative volume elements with continuous fiber.…”
Fused deposition modeling (FDM) is a low-cost additive manufacturing method with moderate tolerances and high design flexibility. Ample studies are being undertaken for modeling the mechanical properties of FDM by using the Finite Element Method (FEM). The process technique of FDM results in anisotropic inner structures that are affected by the chosen manufacturing parameters. Moreover, composite filaments, such as fiber-reinforced polymers, have anisotropy even in filament form before FDM printing. These anisotropic effects are needed to be examined and incorporated for an adequate model. In order to speed up the design stage, we aim to prepare a practical method for simulating the mechanical properties of FDM-printed fiber-reinforced polymer composites. In this work, we computed the homogenized material properties for various fiber lengths, fiber volume percentages, and fiber orientations by asymptotic homogenization at the microscale. Then, mesoscale simulations are carried out through FEM simulations by incorporating the influences of process parameters. In this way, we demonstrate the effect of various micro- and mesostructural features on the homogenized properties step by step.
“…Continuous fiber reinforcement is still an emerging issue for FDM printing. Nevertheless, there are some examples in the literature, 47,48 and we used them as upper threshold and for comparative analysis with the short fibers (0.08 mm and 0.1 mm). We depict 0.1 mm fiber-reinforced RVE in Figure 3, and continuous fiber reinforcement in Figure 2.Figure 2.Representative volume elements with continuous fiber.…”
Fused deposition modeling (FDM) is a low-cost additive manufacturing method with moderate tolerances and high design flexibility. Ample studies are being undertaken for modeling the mechanical properties of FDM by using the Finite Element Method (FEM). The process technique of FDM results in anisotropic inner structures that are affected by the chosen manufacturing parameters. Moreover, composite filaments, such as fiber-reinforced polymers, have anisotropy even in filament form before FDM printing. These anisotropic effects are needed to be examined and incorporated for an adequate model. In order to speed up the design stage, we aim to prepare a practical method for simulating the mechanical properties of FDM-printed fiber-reinforced polymer composites. In this work, we computed the homogenized material properties for various fiber lengths, fiber volume percentages, and fiber orientations by asymptotic homogenization at the microscale. Then, mesoscale simulations are carried out through FEM simulations by incorporating the influences of process parameters. In this way, we demonstrate the effect of various micro- and mesostructural features on the homogenized properties step by step.
“…However, the manufacturing methods for CFR composites, such as traditional lamination, 21 winding, 22 and weaving, 23,24 involve complex processes, high costs, and long cycles. Additive manufacturing technology, known for its low cost and flexibility, offers a new way for the preparation of CFR composite parts 25–29 …”
Inspired by the exceptional strength and toughness of fresh bamboo, a low‐cost method for preparing continuous fiber‐reinforced multi‐matrix composites based on 3D printing was proposed in this paper. Through the design of a special extrusion nozzle, the controllable feed of polylactic‐acid (PLA) and thermoplastic polyurethane (TPU) filaments was achieved, allowing for the preparation of continuous carbon fiber reinforced PLA/TPU composites. The effects of various process parameters on the tensile and flexural properties of the CCFR‐PLA/TPU composites were investigated. Additionally, the relationship between process parameters and the formation of the matrix‐fiber interface and PLA‐TPU interface was analyzed. The results show that layer height has the greatest influence on mechanical properties, while the printing speed has the least influence. The mechanical properties of the CCFR‐PLA/TPU composites and the unreinforced blend matrix, prepared using the optimal combination of process parameters, were tested. The results demonstrated that the tensile strength and flexural strength of the CCFR‐PLA/TPU composites increased by 16.95 and 1.80 times, respectively, compared to the unreinforced blend matrix. Further, inspired by the overall structure of bamboo, a stiffness gradient CCFR composite material was designed and prepared. The methodology employed in this study holds significant implications for the advancement of novel multi‐matrix hybrid continuous fiber reinforced composites, particularly in aerospace and related industries.Highlights
Multi‐matrix continuous fiber reinforced composites were prepared by 3D printing inspired by fresh bamboo.
The effects of process parameters (nozzle temperature, printing speed, extrusion width, layer height) on mechanical properties were investigated.
The optimal printing parameter combination was determined by range analysis.
Stiffness gradient composites were prepared inspired by the overall structure of bamboo.
“…Самым перспективным способом дальнейшего повышения прочности изделий из пластика остается их армирование с помощью непрерывного волокна. Наиболее полный обзор разработанных методов укладки термопластика с непрерывным волокном приведен в [12], а в [13] рассмотрены некоторые важные патенты в этой области.…”
One of the key challenges in additive manufacturing of plastic goods using the Fused Filament Fabrication (FFF) technology is to ensure their strength. The low strength of polymer materials and the distinct anisotropy of their mechanical properties limit the use of 3D printing as an alternative to the traditional small-scale production technologies. The most promising solution to the goal of increasing the strength of printed goods is the application of continuous fiber reinforcement. Several additive manufacturing devices and software products that allow preparing a control program for 3D printing with reinforcement are known, however, having all their advantages, they, like conventional printed products, have a wide spread in strength in various directions (in the plane of a layer and perpendicularly to it, in the direction of growing). In this paper, the authors propose using the continuous fiber reinforcement along the three-dimensional trajectories to smooth out the anisotropy of the products’ properties in the FFF technology and ensure wider possibilities for using them in the production of final goods. In the course of work, a 3D printer with the ability to print using five degrees of freedom and software for preparation of control programs were upgraded for the printing process with laying continuous fiber; printing modes with reinforcement were developed; samples were produced for standard static bending tests. The experiments show that reinforcement improves the printed specimen’s strength, and the proposed three-dimensional reinforcement technique ensures the lower flexing strength compared to standard flat reinforcement with uniaxial laying of fibers, though, the destruction of 3D reinforced specimens occurred without evident delamination.
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