Additive manufacturing of fiber-reinforced polymer composites: A technical review and status of design methodologies

Wong, Janet; Altassan, Abdulmajeed; Rosen, David W.

doi:10.1016/j.compositesb.2023.110603

Cited by 44 publications

(12 citation statements)

References 48 publications

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“…After granulation, the filament consumables were extruded through a micro single-screw extruder (WSJ-12, Shanghai Xin-Shuo Precision Instrument Machinery Co., Ltd.) with a nozzle temperature of 190 °C. Standard 3D printing consumables (diameter 1.70 ± 0.5 mm) were prepared at room temperature through air cooling, a drafting machine, and a winding device. , The composite samples with different fiber contents were printed through a 3D printer (Ender-3S1 Pro, Shenzhen Creative 3D Technology Co., Ltd.) with a nozzle temperature of 200 °C, a platform temperature of 50 °C, and other printing settings (Table S1). Meanwhile, some structures with different texture directions and filling densities were sliced using Ultimaker Cura v16.8 Software.…”

Section: Materials and Methodsmentioning

confidence: 99%

“…Gradually, long filament carbon fiber-reinforced polymerbased composites have been an important research topic. 15 To fully utilize the reinforcing effect of carbon fibers, Zhang, 26 Li, 27 and Abedi 28 et al recently developed a special 3D printing process to achieve filament carbon fiber-reinforced polymer composites, This composite structure is not only beneficial for force dispersion, but also solves the problem of conductive discontinuity. However, filament carbon fibers lack extensibility and are prone to fracture during the molding process, resulting in a high cost and low yield of this special FDM process.…”

Section: Introductionmentioning

confidence: 99%

“…To enrich the functionality of 3D printed polymers, granular or fibrous reinforcing materials are added to the polymer matrix. ,− For example, Peng et al combined the ball-milling strategy with FDM-3D printing technology to design and implement a linear low-density polyethylene (LLDPE)/boron nitride (BN)@graphene nanosheet (GNP) composite parts with dual network structures for high-efficiency thermal conductivity and electrical interference shielding . Li et al innovatively designed the thermoplastic polyurethane (TPU)/Ti 3 C 2 Tx (MXene)/MnFe 2 O 4 /multiwalled carbon nanotube (MWCNT) composite materials using parametric Voronoi structures with different pore sizes and porosity upon FDM-3D printing for sensor and electromagnetic shielding applications .…”

Section: Introductionmentioning

confidence: 99%

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Mechanical, Thermal, and Electrical Properties on 3D Printed Short Carbon Fiber Reinforced Polypropylene Composites

Zhan,

Su,

Tuo

et al. 2024

ACS Appl. Polym. Mater.

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Carbon fiber-reinforced polymer-matrix composites have been an important research topic due to their high performance and versatility. In this study, we investigated the mechanical, thermal, and electrical properties of short carbon fiberreinforced polypropylene (SCF/PP) composites prepared using the fused deposition modeling (FDM)-3D printing technique. PP was selected as the matrix for 3D printed composites to overcome the processing problems caused by the high content of SCFs. The addition of SCFs also effectively mitigated the warping problem during the PP cooling process. Compared to pure PP, the tensile strength increased by up to 35%, and the bending strength exhibited an approximate 40% enhancement. With increasing SCF content, the thermal conductivity exhibited a linear growth, reaching 0.266 W/(m • K) at 70 °C for the PPCF50 sample, simultaneously demonstrating excellent electrical conductivity. The material also displayed significant potential in electromagnetic protection applications, achieving a maximum shielding effectiveness of 29.8 dB. The texture direction and filling density in 3D printing settings have also been proven to play important roles in adjusting the performance of composite samples. The attempt of this study is beneficial for promoting the widespread application of polyolefin polymers as a consumable matrix material for 3D printed SCF-reinforced composite products.

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Section: Materials and Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Mechanical, Thermal, and Electrical Properties on 3D Printed Short Carbon Fiber Reinforced Polypropylene Composites

Zhan,

Su,

Tuo

et al. 2024

ACS Appl. Polym. Mater.

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“…Using fibers to reinforce polymer (thermoplastic, thermoset, or elastomeric-based) has become widespread to obtain high-performance and low-cost composites with flexible designs. 1 When the fibers are compounded with the polymer, the load transfer between the fibers and the polymer can take place through the interface. Fibers with adequate length become the carrier to achieve effective load transfer and limit fracture propagation.…”

Section: Introductionmentioning

confidence: 99%

Bamboo fiber‐reinforced epoxy composites fabricated by vacuum‐assisted resin transfer molding (VARTM): Effect of molding sequence and fiber content

Shi,

Wu,

Zhang

et al. 2023

Polymer Composites

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Fabricating bamboo fiber‐reinforced epoxy composites (BFREs) using the vacuum‐assisted resin transfer molding (VARTM) process has many advantages, such as low cost, high product quality, controllability, and broad applicability. However, the immature fabrication process seriously affects product performance and hinders the full exploitation of the advantages of the VARTM process. The effects on the physical‐mechanical and thermal properties of BFREs by molding sequence and fiber content were investigated in this study. The molding sequence of fiber compression followed by resin injection was beneficial to ensure hermeticity, thus reducing the voids in the BFREs. The mechanical properties of BFREs gradually increased with increasing fiber content. With 50 wt% fiber content, the bending strength and modulus, shear strength, and impact toughness of BFREs reached 71.27 MPa, 6.78 GPa, 11.68 MPa, and 5.45 kJ/m2, respectively. Although the thermal stability of the BFREs was slightly lower than that of pure epoxy, the bamboo fibers' high rigidity evidentially increased the epoxy's dynamic mechanical properties. The life cycle assessment indicated that the BFREs effectively reduced the environmental impacts and production energy consumption compared to the glass fiber correspondent. The VARTM‐fabricated BFREs have great potential for construction, transportation, household items, packaging, sports equipment, and leisure goods applications.Highlights Fiber compression followed by resin injection could ensure great hermeticity. Micro‐CT accurately measured the void characteristics of the composites. Voids had detrimental effects on the properties of the composites. Dense bamboo fiber preforms enhanced the mechanical properties of epoxy. Bamboo fibers reinforcing epoxy reduced the impact on the environment.

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“…Fiber-reinforced composites (FRP) are derived from the modification of polymers with either continuous or short fibers [ 1 , 2 , 3 , 4 , 5 , 6 ]. By combining stiff and strong fibers with lightweight polymer matrices, fiber-reinforced composites offer a high strength-to-weight ratio, excellent processability, and resistance to wear [ 7 , 8 , 9 ]. Polyamide 6 (PA6), as a semi-crystalline polymer, possesses excellent processability and shape ability, along with outstanding wear and corrosion resistance, rendering it an ideal choice for a polymer matrix [ 10 ].…”

Section: Introductionmentioning

confidence: 99%

Fused-Deposition Modeling 3D Printing of Short-Cut Carbon-Fiber-Reinforced PA6 Composites for Strengthening, Toughening, and Light Weighting

Sun,

Mubarak,

Zhang

et al. 2023

Polymers

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Additive manufacturing of carbon-fiber-reinforced polymer (CFRP) has been widely used in many fields. However, issues such as inconsistent fiber orientation distribution and void formation during the layer stacking process have hindered the further optimization of the composite material’s performance. This study aimed to address these challenges by conducting a comprehensive investigation into the influence of carbon fiber content and printing parameters on the micro-morphology, thermal properties, and mechanical properties of PA6-CF composites. Additionally, a heat treatment process was proposed to enhance the interlayer bonding and tensile properties of the printed composites in the printing direction. The experimental results demonstrate that the PA6-CF25 composite achieved the highest tensile strength of 163 MPa under optimal heat treatment conditions: 120 °C for 7.5 h. This corresponds to a significant tensile strength enhancement of 406% compared to the unreinforced composites, which represents the highest reported improvement in the current field of CFRP-fused deposition 3D printing. Additionally, we have innovatively developed a single-layer monofilament CF-OD model to quantitatively analyze the influence of fiber orientation distribution on the properties of the composite material. Under specific heat treatment conditions, the sample exhibits an average orientation angle μ of 0.43 and an orientation angle variance of 8.02. The peak frequency of fiber orientation closely aligns with 0°, which corresponds to the printing direction. Finally, the study explored the lightweight applications of the composite material, showcasing the impressive specific energy absorption (SEA) value of 17,800 J/kg when implementing 3D-printed PA6-CF composites as fillers in automobile crash boxes.

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Additive manufacturing of fiber-reinforced polymer composites: A technical review and status of design methodologies

Cited by 44 publications

References 48 publications

Mechanical, Thermal, and Electrical Properties on 3D Printed Short Carbon Fiber Reinforced Polypropylene Composites

Mechanical, Thermal, and Electrical Properties on 3D Printed Short Carbon Fiber Reinforced Polypropylene Composites

Bamboo fiber‐reinforced epoxy composites fabricated by vacuum‐assisted resin transfer molding (VARTM): Effect of molding sequence and fiber content

Fused-Deposition Modeling 3D Printing of Short-Cut Carbon-Fiber-Reinforced PA6 Composites for Strengthening, Toughening, and Light Weighting

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