Additive Manufacturing of CFRP Composites Using Fused Deposition Modeling: Effects of Process Parameters

Abstract

Fused deposition modeling (FDM) is one of the attractive additive manufacturing (AM) technologies for rapid prototyping with complex structures in a short timeframe. Thermoplastics are currently used as common feedstocks to fabricate prototypes in FDM process. However, FDM-fabricated pure thermoplastic parts cannot be used as load-bearing parts in the actual applications due to their limited tensile strength. Such condition could be improved by developing carbon fiber reinforced plastic (CFRP) composites using FDM for potential industrial end users. It is crucial that proper selections of FDM process parameters during fabricating CFRP composite parts could ensure the part quality and properties. However, the effects of FDM process parameters on the tensile properties of CFRP composites have not been explored. In this paper, CFRP composite specimens with 5 wt% carbon fiber content were fabricated using a FDM machine. Tensile testing was conducted to obtain the tensile properties. The effects of process parameters (including infill speed, nozzle temperature, and layer thickness) on the tensile properties of FDM-fabricated CFRP composite parts were investigated.

Additive manufacturing of thermoplastic matrix composites using fused deposition modeling: A comparison of two reinforcements

“…9–13 With the development of materials and technologies, it has become possible to fabricate ABS thermoplastic matrix composite parts with enhanced tensile properties using FDM. 3,12–17…”

Experimental investigations for preparation of biocompatible feedstock filament of fused deposition modeling (FDM) using twin screw extrusion process

“…16 –19 The previous reported literature suggests that the scaffold material can be synthetic or biological, degradable, or nondegradable depending upon the intended use. 20 –26…”

The Influence of Raster Angle and Moisture Content on the Mechanical Properties of PLA Parts Produced by Fused Deposition Modeling

“…3D printing applications have been expanding rapidly due to the minimal cost of the production process, low supervision and maintenance cost, and simple material change [ 1 ]. Different 3D printing processes have been developed using numerous materials and methods [ 2 , 3 , 4 , 5 , 6 , 7 , 8 , 9 , 10 , 11 , 12 , 13 , 14 , 15 ]. One of the most common 3D printing technologies is fused deposition modeling (FDM), which is a layer-by-layer technique using CAD and computer-aided manufacturing (CAM).…”

“…FDM is a manufacturing process that is affected by many parameters that may alter the quality and mechanical properties of the part. Many researchers have investigated multiple parameters to improve the performance of the 3D-printed parts and components [ 5 , 6 , 7 , 8 , 9 , 10 , 11 , 12 , 13 , 14 , 15 ]. Chacón et al [ 21 ] investigated how the strength and the ductility of PLA specimens are affected by the layer thickness.…”