Composite additive manufacturing of morphing aerospace structures

Fasel, Urban; Keidel, Dominic; Baumann, Leo; Cavolina, Giovanni; Eichenhofer, Martin; Ermanni, Paolo

doi:10.1016/j.mfglet.2019.12.004

Cited by 112 publications

(50 citation statements)

References 9 publications

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“…The first application capable of exploiting the high mechanical performance and manufacturability offered by fibre reinforced FDM was the manufacturing of an aerofoil for an aircraft wing building feasibility study [34,35]. Subsequently, more complex structures, which are time-consuming with conventional manufacturing processes, such as a truss structure for airframe fuselage of a drone [36] or honeycomb structure [19,37], were experimentally studied. Among the studies of the fibre reinforcement in FDM, the critical fibre length, which strongly affects the strength of short fibre composite, has not been considered extensively in the strength of short fibre composite, has not been considered extensively in the available literature.…”

Section: Introductionmentioning

confidence: 99%

Fused Deposition Modelling of Fibre Reinforced Polymer Composites: A Parametric Review

et al. 2021

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Fused deposition modelling (FDM) is a widely used additive layer manufacturing process that deposits thermoplastic material layer-by-layer to produce complex geometries within a short time. Increasingly, fibres are being used to reinforce thermoplastic filaments to improve mechanical performance. This paper reviews the available literature on fibre reinforced FDM to investigate how the mechanical, physical, and thermal properties of 3D-printed fibre reinforced thermoplastic composite materials are affected by printing parameters (e.g., printing speed, temperature, building principle, etc.) and constitutive materials properties, i.e., polymeric matrices, reinforcements, and additional materials. In particular, the reinforcement fibres are categorized in this review considering the different available types (e.g., carbon, glass, aramid, and natural), and obtainable architectures divided accordingly to the fibre length (nano, short, and continuous). The review attempts to distil the optimum processing parameters that could be deduced from across different studies by presenting graphically the relationship between process parameters and properties. This publication benefits the material developer who is investigating the process parameters to optimize the printing parameters of novel materials or looking for a good constituent combination to produce composite FDM filaments, thus helping to reduce material wastage and experimental time.

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Section: Introductionmentioning

confidence: 99%

Fused Deposition Modelling of Fibre Reinforced Polymer Composites: A Parametric Review

et al. 2021

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“…Also, AM parts with CF filled with other materials such as resin composites like polyetherketoneketone (PEKK) are being used in aircraft frames and interiors such as air ducts for cabin ventilation in aerospace applications [ 163 ]. Reference [ 164 ] presents a proof of concept of the applicability of a cost-efficient, automated CF additive manufacturing for morphing aerospace structures (as shown in Figure 15 c), which shows great potential in improving flight performance.…”

Section: Systematic Review Of Current Researchmentioning

confidence: 99%

Scientometric Analysis and Systematic Review of Multi-Material Additive Manufacturing of Polymers

et al. 2021

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Multi-material additive manufacturing of polymers has experienced a remarkable increase in interest over the last 20 years. This technology can rapidly design and directly fabricate three-dimensional (3D) parts with multiple materials without complicating manufacturing processes. This research aims to obtain a comprehensive and in-depth understanding of the current state of research and reveal challenges and opportunities for future research in the area. To achieve the goal, this study conducts a scientometric analysis and a systematic review of the global research published from 2000 to 2021 on multi-material additive manufacturing of polymers. In the scientometric analysis, a total of 2512 journal papers from the Scopus database were analyzed by evaluating the number of publications, literature coupling, keyword co-occurrence, authorship, and countries/regions activities. By doing so, the main research frame, articles, and topics of this research field were quantitatively determined. Subsequently, an in-depth systematic review is proposed to provide insight into recent advances in multi-material additive manufacturing of polymers in the aspect of technologies and applications, respectively. From the scientometric analysis, a heavy bias was found towards studying materials in this field but also a lack of focus on developing technologies. The future trend is proposed by the systematic review and is discussed in the directions of interfacial bonding strength, printing efficiency, and microscale/nanoscale multi-material 3D printing. This study contributes by providing knowledge for practitioners and researchers to understand the state of the art of multi-material additive manufacturing of polymers and expose its research needs, which can serve both academia and industry.

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“…The filament extrusion process (or continuous fiber-reinforced thermoplastic filament extrusion process) stands for printers using readily made fiber-reinforced thermoplastic filaments, which are then simply heated during extrusion before being deposited [ 101 ]. This process is quite convenient, since it splits the complexity of the filament preparation from its printing, thus allowing greater control over each step.…”

Section: Technology Landscape and Future Trendsmentioning

confidence: 99%

Fused Filament Fabrication of Polymers and Continuous Fiber-Reinforced Polymer Composites: Advances in Structure Optimization and Health Monitoring

et al. 2021

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3D printed neat thermoplastic polymers (TPs) and continuous fiber-reinforced thermoplastic composites (CFRTPCs) by fused filament fabrication (FFF) are becoming attractive materials for numerous applications. However, the structure of these materials exhibits interfaces at different scales, engendering non-optimal mechanical properties. The first part of the review presents a description of these interfaces and highlights the different strategies to improve interfacial bonding. The actual knowledge on the structural aspects of the thermoplastic matrix is also summarized in this contribution with a focus on crystallization and orientation. The research to be tackled to further improve the structural properties of the 3D printed materials is identified. The second part of the review provides an overview of structural health monitoring technologies relying on the use of fiber Bragg grating sensors, strain gauge sensors and self-sensing. After a brief discussion on these three technologies, the needed research to further stimulate the development of FFF is identified. Finally, in the third part of this contribution the technology landscape of FFF processes for CFRTPCs is provided, including the future trends.

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Composite additive manufacturing of morphing aerospace structures

Cited by 112 publications

References 9 publications

Fused Deposition Modelling of Fibre Reinforced Polymer Composites: A Parametric Review

Fused Deposition Modelling of Fibre Reinforced Polymer Composites: A Parametric Review

Scientometric Analysis and Systematic Review of Multi-Material Additive Manufacturing of Polymers

Fused Filament Fabrication of Polymers and Continuous Fiber-Reinforced Polymer Composites: Advances in Structure Optimization and Health Monitoring

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