3D printed fiber reinforced polymer composites - Structural analysis

Abstract

In this research, mechanical and structural properties of Continuous Fiber Reinforced Additively Manufactured (CFRAM) components are studied. Structural analysis is performed to understand the failure behavior of CFRAM components. Based on the SEM analysis of the tested parts, correlations between results of the mechanical test and microstructure of the parts have been investigated. CFRAM components are lightweight yet strong materials with a wide range of potential applications in auto industry, aerospace, sport goods, and medical tools. CFRAM components benefit from both cutting-edge 3D printing technology and fiber reinforcement to improve mechanical properties. Produced parts have lightweight compared with metals, strong mechanical properties, and short manufacturing time. In addition, thermoplastic polymer used for CFRAM components makes product recyclable. In this study, samples were printed using Markforged Mark Two printer and the effect of the fiber type, fiber orientations, infill density, and temperatures on tensile, fatigue, and creep properties were investigated. Carbon fiber (CF), fiberglass (FG), and Kevlar were used as reinforcing agents, and nylon as the base material. Microstructural analysis was conducted to investigate the fracture mechanism, morphology, and printing quality of the specimens. It was observed that the main failing mechanisms for CFRAM components are fiber pull-out, fiber breakage, and delamination. Further, it was understood that there is a correlation between the fiber stacking density and mechanical properties. Overall, the information provided in this study reports a unique knowledge base about the mechanical and structural behaviours of the components built with the CFRAM technology.