Process-Induced Fiber Orientation in Fused Filament Fabrication

Mulholland, Tom; Goris, Sebastian; Boxleitner, Jake; Osswald, Tim A.; Rudolph, Natalie

doi:10.3390/jcs2030045

Cited by 36 publications

(18 citation statements)

References 16 publications

(16 reference statements)

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“…The 450CA30 failed adhesively between the layers as was to be expected due to the onset of crystallization before the next layer could be deposited. As fibre alignment is mostly in the extrusion direction, 14,15 or at least in the layer plane, we assume the same maximum strength for the Z direction as achieved for the small‐scale slow crystallizing material. This results in a 42.07% relative maximum strength based on the averages and 44.76% based only on the maximum values, which is very close to the calculated degree of bonding of 42.54%.…”

Section: Resultsmentioning

confidence: 99%

Interlaminar strength in large‐scale additive manufacturing of slow crystallizing polyaryletherketone carbon composites

Consul

Chaplin

Tagscherer

et al. 2020

Polymer International

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Fusion bonding theory is applied to the additive manufacturing process to predict the strength developed across the interface between the deposited layers in material extrusion based large‐scale additive manufacturing. Relaxation times were determined through rheology investigations of the neat polymers and were extrapolated across the entire process temperature range to estimate the required welding times for optimal bond formation. For the calculation of bond formation during cooling from the melt, the semicrystalline polyaryletherketone is considered amorphous until the onset of crystallization which is determined by recreating the process thermal history in DSC measurements. A significant improvement in bond development during additive manufacturing is achieved through the use of specifically designed polymers with slower crystallization kinetics. Both in small‐scale additive manufacturing, achieving full bonding, and in large‐scale additive manufacturing, they achieve significantly higher interlaminar strength than the reference material, validated by three‐point bending. A very good match between the estimated degree of bonding and the tested strength of upright printed specimens in three‐point bending was found. While the fusion bonding model calculates a degree of bonding of 42.07%, mechanical testing showed 42.54% of the bulk flexural strength. The study outlines a procedure to evaluate materials for additive manufacturing by material extrusion based on small material samples to shorten and improve the process development. © 2020 The Authors. Polymer International published by John Wiley & Sons Ltd on behalf of Society of Industrial Chemistry

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Section: Resultsmentioning

confidence: 99%

Interlaminar strength in large‐scale additive manufacturing of slow crystallizing polyaryletherketone carbon composites

Consul

Chaplin

Tagscherer

et al. 2020

Polymer International

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“…The addition of fibre reinforcement increase the viscosity of the bulk material in molten state [ 28 ] and they increase the heat capacity and heat conductivity [ 29 , 30 ]. This changes the temperature profile during and after deposition which also affects the polymer viscosity and bonding process between printed tracks.…”

Section: Methodsmentioning

confidence: 99%

Fabrication and Characterisation of Aligned Discontinuous Carbon Fibre Reinforced Thermoplastics as Feedstock Material for Fused Filament Fabrication

2020

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In this work, aligned discontinuous fibre composite (ADFRC) tapes were developed and investigated as precursors for a novel 3D printing filament. ADFRCs have the potential to achieve mechanical performance comparable to continuous fibre reinforced composites, given sufficient fibre length and high level of alignment, and avoid many of the manufacturing difficulties associated with continuous fibres, e.g., wrinkling, bridging and corner radii constraints. Their potential use for fused filament fabrication (FFF) techniques was investigated here. An extensive down-selection process of thermoplastic matrices was performed, as matrix properties significantly impact both the processing and performance of the filament. This resulted in four candidate polymers (ABS, PLA, Nylon, PETG) which were used to manufacture ADFRC tapes with a Vf of 12.5% using the high performance discontinuous fibre (HiPerDiF) technology and an in-house developed continuous consolidation module. Tensile stiffness and strength up to 30 GPa and 400 MPa respectively were recorded, showing that a discontinuous fibre filament has the potential to compete with continuous fibre filaments.

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“…However, the article did not present any quantitative data of approximate fiber alignment. In a recent study by Mulholland et al., 63 the orientation in the bead was measured using micro-computed tomography. The results showed the orientation-tensor in the printed bead along the principal flow direction, a 11 was about 0.65.…”

Section: Numerical Modeling Of Fff Processmentioning

confidence: 99%

“…The orientation state in the bead printing direction referred to as a 11 is reported as discrete values of 0.68 and 0.8 for printed laminate and single bead, respectively. 63 The tensile strength and elastic modulus of the nanocomposites are the highest when the samples are loaded along the bead-printing direction as opposed to other orientations. However, the effects of other process parameters like the printing speed, solidification rate, layer thickness are not included in this section.…”

Section: Structure-property Relationship Of Two-phase Materialsmentioning

confidence: 99%

Review on process model, structure-property relationship of composites and future needs in fused filament fabrication

Papon

Haque

2020

Journal of Reinforced Plastics and Composites

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This paper presents the state-of-the-art of additive manufacturing of composites for processing functional, load-bearing components. A general overview of different additive manufacturing methods is provided, and specific attention is focused on fused filament fabrication-based composites processing. Different process modeling strategies are summarized, and key aspects of these models are discussed. Significant results such as thermal and fluid flow characteristics, effects of nozzle geometry on melt flow, fiber orientation, bead spreading, and solidification, the formation of residual stresses, and deformation behavior are discussed from computational modeling perspective. The scientific advancement, model limitations, and future modeling needs are prescribed reviewing the current works. A general overview of material development in nano-micro-macro-scale reinforcement is also presented. Different length-scales of reinforcement has its own challenges and promises. The continuous fiber reinforcement has a great potential for being the next-generation composites manufacturing technology. However, the challenges in reducing the void content, better bonding between the fiber–matrix, and layer-layer adhesion, and process uncertainty are some of the key areas yet to advance. Based on the current limitations on computational modeling, materials development, and process modeling studies, future research needs and recommendations are provided.

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Process-Induced Fiber Orientation in Fused Filament Fabrication

Cited by 36 publications

References 16 publications

Interlaminar strength in large‐scale additive manufacturing of slow crystallizing polyaryletherketone carbon composites

Interlaminar strength in large‐scale additive manufacturing of slow crystallizing polyaryletherketone carbon composites

Fabrication and Characterisation of Aligned Discontinuous Carbon Fibre Reinforced Thermoplastics as Feedstock Material for Fused Filament Fabrication

Review on process model, structure-property relationship of composites and future needs in fused filament fabrication

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