Failure Prediction in 3D Printed Kevlar/Glass Fiber-Reinforced Nylon Structures with a Hole and Different Fiber Orientations

Abstract

This study examined the mechanical performance of 3D-printed, fiber-reinforced composites with a rectangular shape and a hole at one end. Nyon-6 was selected as a polymer matrix, and glass or Kevlar fibers were selected as continuous fibers due to their wide range of applications. Nylon is an engineering thermoplastic; reinforcing it with fibers, such as glass fiber or Kevlar, can significantly improve its mechanical properties. An analytical model was constructed based on the volume average stiffness approach to predict the mechanical properties of 3D-printed specimens. A numerical model was built to predict failure modes and damage in 3D-printed specimens with different fiber orientations. The stress–strain relationship was linear in all composites. For Kevlar-based composites, the maximum stress was 1.7 MPa, 3.62 MPa, 2.2 MPa, 1.0 MPa, and 1.4 MPa for the orientation angles of 0°, 22.5°, 45°, 67.5°, and 90°, respectively. Overall, Kevlar-based composites exhibited mechanical properties superior to those of glass-based composites. The effect of the fiber orientation was also different between the two systems. The simulation results predicted that the failure propagation begins in the areas close to the hole. Notably, the level of agreement between the simulated and experimental results varied depending on the fiber type and orientation, reflecting the complex interplay between multiple fibers, matrix interactions, and stress transfer.

A Comparative Evaluation of the Effects of Manufacturing Parameters on Mechanical Properties of Additively Manufactured PA and CF-Reinforced PA Materials

“…Chopped reinforced filaments could be custom-made with an intended percentage of fibers (carbon, glass, or Kevlar) or there are also commercial pre-impregnated filaments. Low density, low thermal expansion, and thermal conductivity make CF stand out compared to other reinforcements [ 7 , 9 , 10 ].…”

Effects of Raster Angle on the Elasticity of 3D-Printed Polylactic Acid and Polyethylene Terephthalate Glycol

“…The process of additive manufacturing (AM), commonly known as 3D printing, has grown in popularity over the last decade due to its adaptability in generating a wide range of items with complicated geometries and unique mechanical qualities at a cheap cost. The development in the availability of 3D printers and the affordability of printing materials has fueled the rise in the use of 3D printing in recent years [1]. It is a technology that allows for the fabrication of parts with complicated geometry by creating them layer by layer on an optimized platform using computer-aided manufacturing and design.…”

“…This technology is capable of printing almost any material (e.g., biological materials, polymers, ceramics, alloys and metals, etc. ), allowing for a diverse range of products in engineering applications such as aerospace, civil engineering, biomedical, and automotive sectors [1][2][3]. One critical aspect that influences the performance of 3D-printed objects is their mechanical properties [4].…”