An innovative design approach in three-dimensional printing of continuous fiber–reinforced thermoplastic composites via fused deposition modeling process: In-melt simultaneous impregnation

材料科学 复合材料 熔融沉积模型 纤维 挤压 玻璃纤维 极限抗拉强度 纤维缠绕 沉积(地质) 喷嘴 复合数 3D打印 机械工程 古生物学 工程类 生物 沉积物
作者
Behnam Akhoundi,Amir Hossein Behravesh,Arvin Bagheri Saed
出处
期刊:Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture [SAGE Publishing]
卷期号:234 (1-2): 243-259 被引量:81
标识
DOI:10.1177/0954405419843780
摘要

In this study, an innovative method was devised and implemented to produce continuous glass fiber–reinforced thermoplastic composites via a fused deposition modeling three-dimensional printer to enhance the mechanical properties of the printed products. In the extrusion-based, or filament-based, additive manufacturing process, namely, fused deposition modeling, the parts are basically formed via deposition of the material in the molten state, and thus embedding continuous fiber, in a solid form, is highly challenging. Hence, a nozzle system was designed and manufactured to feed the continuous fiber into the molten polymer simultaneously, which is called, here, in-melt simultaneous impregnation. With the presence of continuous fibers in the nozzle outlet, the feed of filament was calculatedly adjusted in the G-codes depending on the fiber volume percentage, to produce sound flow, and consistent deposition. Composite products were produced with various geometrical shapes. Via analysis and close control of the filament feeding, as a critical requirement to produce a sound printed product, composites with various fiber volume percentages were printed. Also, the mechanical properties of the printed parts with 30% by volume of glass fiber were measured. The results of the tensile test indicated that the continuous fibers were appropriately and effectively embedded that could result in remarkable increases in tensile strength and modulus of the samples, higher than 700%. The resulted values of tensile modulus were consistent with the values calculated via the rule of mixture. In addition, scanning electron microscopic images of the fracture sections suggest a sound adhesion between fibers and the matrix.
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