Development, Testing, and Thermoforming of Thermoplastics Reinforced with Surface-Modified Aramid Fibers for Cover of Electronic Parts in Small Unmanned Aerial Vehicles Using 3D-Printed Molds

Abstract

This paper presents the development, characterization, and testing of PP/PE-g-MA composites with 10 and 15 wt% surface-modified aramid fibers, and aluminum-based pigment, as covers for a small drone body for collision protection. The successful fiber surface modification with SiO2 by the sol–gel method using TEOS was confirmed by FTIR, SEM, and EDS analyses. The composites were characterized by FTIR and SEM analyses and surface energy and water contact angle measurements and tested in terms of tensile, flexural, impact, and thermal properties. The materials exhibited hydrophobic character and compact and uniform morphostructures, with increased surface energy with fiber content owed to improved adhesion between modified fibers and the matrix. Compared to the control sample, composites with modified fibers showed an increase by 20% in tensile strength, and 36–52% in the modulus, and an increase by 26–33% in flexural strength and 30–47% in the modulus, with higher values at room temperature. Impact resistance of modified fiber composites showed an increase by 20–40% compared to the control sample, due to improved interaction between SiO2-modified fibers and maleic anhydride, which inhibits crack formation, allowing higher energies’ absorption. The composites were vacuum-thermoformed on 3D-printed molds as a two-part cover for the body of a drone, successfully withstanding the flight test.