Tailoring strength and modulus by 3D printing different continuous fibers and filled structures into composites

AbstractThree-dimensional (3D) printing is one of potential technologies for production of designable complex filled structures and mechanical strengthening along the reinforcing fibers for composites. The objective of this paper is to study the tensile mechanical behavior of diverse concentric fiber rings and fiber layers using glass fiber (GF), Kevlar fiber (KF), and carbon fiber (CF) printed into polymer composites and then to compare them. Additionally, it also aims to identify the influence of complex filled structures of Nylon on different fiber printed polymer composites. Tensile tests and scanning electron microscope (SEM) were utilized to characterize the 3D printed composites. Results revealed that CF-printed composite exhibits the greatest tensile strength of 110 MPa and modulus of 3941 MPa as compared to glass and Kevlar fiber composites. Increase of concentric fiber rings and fiber layers is attributed to increase in tensile strength and modulus. Also, the rectangular filled structure of Nylon declared the highest tensile strength and modulus than hexagonal and triangular filled structure owing to its rectangular filling that bears maximum load in longitudinal direction. Graphical abstractContinuous fiber 3D printing apparatus used to print different fibers and structures for tailoring the tensile strength and elastic modulus.

[1]  W. Zhong,et al.  Short fiber reinforced composites for fused deposition modeling , 2001 .

[2]  D. Lin,et al.  A review on additive manufacturing of polymer-fiber composites , 2017 .

[3]  Chang‐jun Liu,et al.  Three‐dimensional Printing for Catalytic Applications: Current Status and Perspectives , 2017 .

[4]  Dichen Li,et al.  Interface and performance of 3D printed continuous carbon fiber reinforced PLA composites , 2016 .

[5]  A. Todoroki,et al.  3D Printing of Continuous Carbon Fibre Reinforced Thermo-Plastic (CFRTP) Tensile Test Specimens , 2016 .

[6]  A. Issam,et al.  Effect of Methylene Spacers of Unsaturated Polyester Resins on the Properties of Composites Based on Oil Palm Empty Fruit Bunches and Fiberglass , 2011 .

[7]  Robert J. Strong,et al.  A review of melt extrusion additive manufacturing processes: I. Process design and modeling , 2014 .

[8]  Mehrdad Haghi,et al.  Deposition direction-dependent failure criteria for fused deposition modeling polycarbonate , 2014 .

[9]  A. Todoroki,et al.  Three-dimensional printing of continuous-fiber composites by in-nozzle impregnation , 2016, Scientific Reports.

[10]  Garrett W. Melenka,et al.  Evaluation and prediction of the tensile properties of continuous fiber-reinforced 3D printed structures , 2016 .

[11]  L. Love,et al.  The importance of carbon fiber to polymer additive manufacturing , 2014 .

[12]  W. Srubar,et al.  Experimental and theoretical investigation of prestressed natural fiber-reinforced polylactic acid (PLA) composite materials , 2016 .

[13]  R. K. Ohdar,et al.  Parametric appraisal of fused deposition modelling process using the grey Taguchi method , 2010 .

[14]  Yingguang Li,et al.  Rapid prototyping of continuous carbon fiber reinforced polylactic acid composites by 3D printing , 2016 .

[15]  Barry Berman,et al.  3D printing: the new industrial revolution , 2012, IEEE Engineering Management Review.

[16]  K. Lozano,et al.  Nanofiber-reinforced polymers prepared by fused deposition modeling , 2003 .

[17]  K. McDonnell,et al.  Fabrication of Continuous Carbon, Glass and Kevlar fibre reinforced polymer composites using Additive Manufacturing , 2017 .

[18]  Masahito Ueda,et al.  Bending fracture rule for 3D-printed curved continuous-fiber composite , 2018, Journal of the Japan Society for Composite Materials.

[19]  M. Cima,et al.  Three-Dimensional Printing: Rapid Tooling and Prototypes Directly from a CAD Model , 1990 .

[20]  Frederik L. Giesel,et al.  3D printing based on imaging data: review of medical applications , 2010, International Journal of Computer Assisted Radiology and Surgery.

[21]  W. Cong,et al.  Additive manufacturing of carbon fiber reinforced thermoplastic composites using fused deposition modeling , 2015 .

[22]  L. Love,et al.  Highly oriented carbon fiber–polymer composites via additive manufacturing , 2014 .

[23]  Brian N. Turner,et al.  A review of melt extrusion additive manufacturing processes: II. Materials, dimensional accuracy, and surface roughness , 2015 .