A parametric study and characterization of additively manufactured continuous carbon fiber reinforced composites for high-speed 3D printing

Pappas, John M.; Thakur, Aditya R.; Leu, Ming C.; Dong, Xiangyang

doi:10.1007/s00170-021-06723-1

Cited by 30 publications

(18 citation statements)

References 34 publications

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“…In the above, H and S are material coefficients related to the fiber suspension system. H f is determined via Equation (11). S is set to be zero since a slender-bodytheory-based model is adopted in the Dinh-Armstrong model, which assumes the particle's thickness can be ignored.…”

Section: Damentioning

confidence: 99%

“…5,6 Experimental studies examined the correlations between the macro mechanical performances and microstructural formation of LAAM-produced composite parts. [7][8][9][10][11][12] Nevertheless, to better understand the material behaviors of LAAM-produced parts, it is vital to identify the material flow and associated fiber orientation of the molten feedstock through the nozzle extrusion and the sequential deposition process. 13 Nixon et al 14 explored the fiber orientation state within a nozzle die used in extrusion deposition additive manufacturing applications.…”

Section: Introductionmentioning

confidence: 99%

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A numerical study on the predicted fiber orientation of large area extrusion deposition additive manufactured composites

Wang

2022

Polymer Composites

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The recent‐emerging Large Area extrusion deposition Additive Manufacturing (LAAM) provides a low‐cost and high‐efficient alternative manufacturing approach for industries like automotive and aerospace. Fiber orientation information significantly determines the material performances of LAAM‐produced short fiber reinforced composites. Numerical studies have been performed to better understand the microstructural formation of the fiber orientation in deposited beads. The fully coupled flow/orientation analysis approach has been applied for LAAM deposition flow modeling. In contrast, the orientation analysis is still limited to the classic Folgar‐Tucker Isotropic Rotary Diffusion (IRD) model. This paper employs the advanced principle Anisotropic Rotary Diffusion Reduced Strain Closure (pARD‐RSC) orientation evaluation model to estimate the fiber alignment of the LAAM flows, which is firstly used in the simulations of extrusion deposition flows with free surface boundaries. The effects of constant parameters of the pARD‐RSC model are investigated. It is found that predicted fiber orientation results in the flow end are primarily sensitive to the value of the strain slip factor. The initial fiber orientation condition of the flow inlet is also studied. By comparing the computed results with experimentally reported data, it is found that the initial fiber orientation state of the flow inlet significantly impacts the fiber alignment patterns in the deposited beads.

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Section: Damentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

A numerical study on the predicted fiber orientation of large area extrusion deposition additive manufactured composites

Wang

2022

Polymer Composites

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“…Several research studies have reported 3D printing structures reinforced with different kinds of short fibers or inclusions [5][6][7][8][9]. One of the latest efforts in this direction has been made through the application of Continuous Fiber Fabrication (CFF) 3D printing machines, which lay continuous composite fibers, such as Kevlar and carbon fiber, inside 3D printed thermoplastics to improve their mechanical properties [10][11][12][13][14][15]. Blok et al [16] investigated and compared these two different methods of composite 3D printing, continuous fiber printing and short fiber printing, in terms of their mechanical properties, part quality and 3D printing versatility.…”

Section: Introductionmentioning

confidence: 99%

Mechanical and FEA-Assisted Characterization of 3D Printed Continuous Glass Fiber Reinforced Nylon Cellular Structures

et al. 2021

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The main objective of this study was to investigate the mechanical behavior of 3D printed fiberglass-reinforced nylon honeycomb structures. A Continuous Fiber Fabrication (CFF) 3D printer was used since it makes it possible to lay continuous strands of fibers inside the 3D printed geometries at selected locations across the width in order to optimize the bending behavior. Nylon and nylon/fiberglass honeycomb structures were tested under a three-point bending regime. The microstructure of the filaments and the 3D printed fractured surfaces following bending tests were examined with Scanning Electron Microscopy (SEM). The modulus of the materials was also evaluated using the nanoindentation technique. The behavior of the 3D printed structures was simulated with a Finite Element Model (FEM). The experimental and simulation results demonstrated that 3D printed continuous fiberglass reinforcement is possible to selectively adjust the bending strength of the honeycombs. When glass fibers are located near the top and bottom faces of honeycombs, the bending strength is maximized.

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“…Varying flow rates cause irregularities in the extruded material, consequently introducing weaker spots in the deposited structure (Pappas et al, 2021). Control of the flow rate through the extruder motor is difficult as its extrusion rate reacts with a time delay to a change of the extruder motor speed due to the back pressure within the hot end (Choulak et al, 2004).…”

Section: Trajectory Trackingmentioning

confidence: 99%

Algorithms for Large Scale Additive Manufacturing in a Free-Flying Environment

Tauscher

Jonckers

Thakur

2022

Front. Space Technol.

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Large scale additive manufacturing (LSAM) refers to the fabrication of structures that exceed the build volume of conventional additive manufacturing setups. This can be used for in-space manufacturing (ISM), facilitating the production of large functional structures in space which cannot fit within the payload fairing of a launcher system. In this paper, a new approach for a continuous fabrication process of structural elements is presented, combining the reach of a free-flying satellite and a robotic arm, utilizing a fused filament fabrication (FFF) 3D-printing setup. A motion planning algorithm was developed which calculates energy-efficient movement trajectories based on a truss design input combined with the movement constraints of the satellite and robotic arm. Using this printing paradigm, a long support-free truss was manufactured. This approach was further elevated by extending the truss structure along the second planar axis, thus facilitating the manufacture of structures larger than generally possible through a layer-by-layer approach. Subsequently, combining the segmented and continuous printing approach, a planar truss structure was produced.

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A parametric study and characterization of additively manufactured continuous carbon fiber reinforced composites for high-speed 3D printing

Cited by 30 publications

References 34 publications

A numerical study on the predicted fiber orientation of large area extrusion deposition additive manufactured composites

A numerical study on the predicted fiber orientation of large area extrusion deposition additive manufactured composites

Mechanical and FEA-Assisted Characterization of 3D Printed Continuous Glass Fiber Reinforced Nylon Cellular Structures

Algorithms for Large Scale Additive Manufacturing in a Free-Flying Environment

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