Fabrication of complex 3D composites by fusing automated fiber placement (AFP) and additive manufacturing (AM) technologies

Abstract

Automated fiber placement (AFP) is emerging as one of the advanced methods toward fabrication of polymer matrix based composite structures. This automated technique focuses on polymer composite manufacturing for use in a wide range of automotive and aerospace applications. The AFP process offers an elevated level of customization through the possibility of placing each individual tow at custom-designed trajectories. Additive manufacturing (AM) method, on the other hand, has the potential to fabricate functional end user parts of complex geometries, thus eliminating the need for costly tooling, multi-step processing and fasteners or joints. This paper will highlight the potential of fusing AFP and AM processes to fabricate complex 3D polymer based composite parts. A combination of these two processes suggests a promising option for composite materials development, improving composite structures in terms of complexity and customizability. The paper presents the adopted research methodology, background research, the design, development and set up of an experimental workcell that fuses AM and AFP, and the design methodology which is required to design complex composite parts using the proposed manufacturing process. Main challenges and opportunities are discussed, such as how restrictions of conventional composite production can be eased, and additional freedoms of design can be achieved.

Embedding Ultra-High-Molecular-Weight Polyethylene Fibers in 3D-Printed Polylactic Acid (PLA) Parts

“…While the manual laying of fibers is labor intensive and error prone, automation of the fiber laying process is possible as it is shown in literature [39,40]. A number of techniques currently in the market could be applied to manufacture parts using such composites.…”

Recent developments in manufacturing, mechanics, and design optimization of variable stiffness composites

“…The process is utilized for thermoplastic composites as they do not require autoclave curing. Raspall et al 69 also proposed a combined AFP and AM process for fiber-reinforced composites. The fixed AM delivery head provides geometric-specific thermoplastic substrate/mold for the AFP step.…”

Isogeometric static analysis of laminated plates with curvilinear fibers based on Refined Zigzag Theory

“…Thus, the load transfer can be carried over the curvilinear fibers instead of resin. Various studies have been conducted to facilitate the placement of curvilinear tows from the manufacturing point of view [33][34][35]. In addition, the optimization of variable stiffness composites by maximizing its mechanical strength have been studied in a great detail to determine optimal fiber angles throughout the composite structure.…”