Void Content Reduction in 3D Printed Glass Fiber-Reinforced Polymer Composites through Temperature and Pressure Consolidation

Abstract

To improve the properties of additively manufactured parts to be used in high-end applications, intrinsic defects occurring during the printing process need to be minimized. Defects such as void can significantly degrade the mechanical properties of the resulted parts. The presence of void is more evident in composite printed parts due to the inhomogeneity of the specimen. In this study, composite rectangular coupons printed with a Markforged Mark Two printer were manufactured with different fiber orientations and stacking sequences. A void content reduction/consolidation process, consisting of applying pressure at different temperature levels, was developed and implemented to remove the voids in form of air bubbles trapped in the specimen. A two-part mold with female and male components with the same dimensions as the rectangular specimen was designed and machined to be used in a hot press process. The success of the approach was evaluated by calculating the density of the specimen pre- and post-consolidation. The void content reduction results were highly dependent on fiber orientation; however, the density increased for all tested specimens, confirming the reduction in porosity.

Engineered Interleaved Random Glass Fiber Composites Using Additive Manufacturing: Effect of Mat Properties, Resin Chemistry, and Resin-Rich Layer Thickness

“…Another important aspect of composite manufacturing is the introduction of voids during manufacturing [31,32]. The voids act as defects that can cause premature failure of the specimen.…”