3D printing of short fiber reinforced composites via material extrusion: Fiber breakage

Yang, Zhiyuan; Yang, Zeshi; Chen, Hui; Yan, Wentao

doi:10.1016/j.addma.2022.103067

Cited by 16 publications

(16 citation statements)

References 33 publications

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“…Fiber Deformation. Several previously published experimental results 20,21 show that the carbon fibers could break when flowing in the nozzle, which leads to the decrease of fiber length. This is believed to be caused by substantial fiber deformation.…”

Section: Fiber Orientationmentioning

confidence: 98%

“…More successful applications of FEM were reported, e.g., in the work of Heller et al 27 and Papon et al 28 who discussed the flow behavior of molten matrix and the mechanical properties of products during the FDM process by which the details between fuse flow and stress distribution were given. Croom et al 29 and Yang et al 21 carried out single-phase computational fluid dynamics (CFD) simulations to study the influence of nozzle shape on the flow behavior of molten matrix. Using the knowledge provided by numerical simulations, several phenomena that were numerically observed but could hardly be explained by physical experiments were discussed.…”

Section: Introductionmentioning

confidence: 99%

“…They found that fiber breakage occurs primarily as the molten material passes through the nozzle constriction area, and the relative motion between the nozzle and the printing bed causes the fibers to orient more randomly. Yang et al 21 made quantitative statistics on fiber fracture and orientation change during FDM. Their results showed the relationship between fiber breakage and material strength: The fewer the fiber breaks, the better the mechanical properties.…”

Section: Introductionmentioning

confidence: 99%

“…The numerical studies of Yang et al and Zhang et al are useful for providing the orientation, distribution, and deformation of fibers with complex interparticle and fluid–solid collisions. However, the deformation and fracture of fibers were entirely ignored by Zhang et al On the other hand, Yang et al only carried out 2D numerical simulations with flexible carbon fibers and the interaction among the long fibers are not considered, which has been proved to be critical to influence the final products. , The current study thus aims to fill this research gap. Here, the CFD-DEM model of Zhang et al for nonflexible particles is extended to flexible fibers and the corresponding effects are fully discussed.…”

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

CFD-DEM Investigation on Effects of Fiber Deformation during 3D Printing Process Based on Fused Deposition

Guo

Zhang

et al. 2023

Ind. Eng. Chem. Res.

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In this study, a coupled computational fluid dynamics and discrete element method (CFD-DEM) model is constructed to deal with the motion of flexible fibers in molten thermoplastic during fused deposition modeling (FDM) 3D printing process. The effects of fiber stiffness and length on fiber bridging and nozzle clogging are investigated. Numerical results show that fiber deformation has a clear influence on nozzle clogging even when the fibers are as short as 0.24 mm for the printing of short carbon fiber reinforced polyamide-6 (sCF/PA6) composite with a fiber volume fraction of 13.34%. Through a particle-scale analysis on the fiber architecture in terms of coordinate number, contact force, and fiber orientation, the influence of fiber deformation is identified. It is found that the flexible fibers are more sensitive to the geometry and profile changes of the nozzle internal walls, which leads to a larger inclination of the flexible fiber in the nozzle. Complex interlocking structures are formed by flexible fibers in the printer nozzle, promoting the fiber bridges. The results of this paper provide insights for the development and optimization of printer nozzles to enable the printing of longer fibers without potential nozzle clogging.

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Section: Fiber Orientationmentioning

confidence: 98%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

CFD-DEM Investigation on Effects of Fiber Deformation during 3D Printing Process Based on Fused Deposition

Guo

Zhang

et al. 2023

Ind. Eng. Chem. Res.

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“…Fibre reinforcement is an effective approach to alleviate the drawback of ME-printed thermoplastic applied in the industry. Recent developments in available materials for ME enabled the printing of carbon nanotube [ 29 , 30 ], graphite [ 31 , 32 ], short carbon fibre [ 19 , 33 , 34 , 35 ], short glass fibre [ 36 , 37 ], short basalt fibre [ 38 , 39 ] and continuous fibre [ 40 , 41 , 42 , 43 ]- reinforced polymer composites. The fibre reinforcements significantly improve the mechanical properties of ME-printed parts.…”

Section: Introductionmentioning

confidence: 99%

Effect of Manufacture-Induced Interfaces on the Tensile Properties of 3D Printed Polyamide and Short Carbon Fibre-Reinforced Polyamide Composites

Hou

Panesar

2023

Polymers

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This study aims to elucidate the structure–property–process relationship of 3D printed polyamide and short carbon fibre-reinforced polyamide composites. The macroscopic properties (tensile modulus) of the 3D printed samples are quantitatively correlated to the printing process-induced intrinsic microstructure with multiple interfaces. The samples were printed with different layer thicknesses (0.1, 0.125 and 0.2 mm) to obtain the varied number of interface densities (number of interfaces per unit sample thickness). The result shows that the printed short carbon fibre-reinforced polyamide composites had inferior partially bonded interfaces compared to the printed polyamide, and consequently exhibited interface-dependent elastic performance. The tensile modulus of 3 mm thick composites decreased up to 18% as a function of interface density, whilst the other influencing aspects including porosity, crystallinity and fibre volume fraction (9%) were the same. Injection moulding was also employed to fabricate samples without induced interfaces, and their tensile properties were used as a benchmark. Predictions based on the shear-lag model were in close agreement (<5%) with the experimental data for the injection-moulded composites, whereas the tensile modulus of the printed composites was up to 38% lower than the predicted modulus due to the partial bonded interfaces.

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Investigation on process window of 3D printed continuous glass fiber‐reinforced thermosetting composites

Najafloo,

Rezadoust,

Latifi

2023

Polymer Composites

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Abstract3D‐printed continuous fiber composites offer high strength in desired directions, which has attracted researchers' attention. In general, thermoset composites provide better results than their thermoplastics counterparts due to their higher modulus, low viscosity resin, better fiber impregnation, and proper adhesion to the reinforcing fibers. This study, examined the fabrication of continuous fiber‐reinforced thermoset composites (CFTCs) using 3D printing technology. This investigation focused on the optimization of process parameters for UV‐curable composites. Using systematic experimentation, the proper nozzle diameter (2.0 mm), print thickness (0.6 mm), and print speed (200 mm/min) were determined, resulting in the attainment of optimal fiber weight ratio and impregnation. The optimized CFTC exhibited an exceptional ultimate tensile strength of 276.26 MPa, exceeding existing literature data on printed short fiber composites. Additionally, under flexural loading conditions, an ultimate strength of 76.7 MPa was observed, which is characterized by a more ductile failure than a brittle fracture mode. The results of this research demonstrate the significant potential of 3D‐printed CFTCs and establish a robust process window for achieving exceptional mechanical properties. These findings hold promise for a wide range of applications demanding high‐strength composite materials.Highlights Continuous fiber reinforced thermoset composites successfully printed. Determination of a process window for printed CFTCs. The optimized CFTC exhibited a remarkable ultimate tensile strength of 276.26 MPa. Ultimate strength of 76.7 MPa was achieved under flexural loading.

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3D printing of short fiber reinforced composites via material extrusion: Fiber breakage

Cited by 16 publications

References 33 publications

CFD-DEM Investigation on Effects of Fiber Deformation during 3D Printing Process Based on Fused Deposition

CFD-DEM Investigation on Effects of Fiber Deformation during 3D Printing Process Based on Fused Deposition

Effect of Manufacture-Induced Interfaces on the Tensile Properties of 3D Printed Polyamide and Short Carbon Fibre-Reinforced Polyamide Composites

Investigation on process window of 3D printed continuous glass fiber‐reinforced thermosetting composites

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