3D printing of multidirectional composite materials reinforced with continuous fibres: impact damage behaviour

Abstract

3D printing is a promising additive manufacturing technology capable of producing functional parts of continuous fibre reinforced thermoplastic composites (CFRTPCs). Thus recyclable parts having complex geometries are obtained in a simple manner [1]. In addition, the use of thermoplastic polymers significantly reduces the manufacturing costs because, unlike thermoset polymers, autoclave is not required for curing purposes. This is one of the greatest opportunities for 3D printing as an alternative to conventional manufacturing processes [2, 3]. Pieces obtained from both, conventional manufacturing methods and 3D printing technology, consists on a sequence of stacked sheets. Although greater automation and the possibility to optimize the design of each sheet are advantages of 3D printing, the adhesion between the matrix and the reinforcement fibres is insufficient and consequently, parts with inferior mechanical properties are obtained. Some studies have been interested in the effect of different process parameters on the mechanical performance of the printed parts, however, further research is required. A fundamental challenge is to get good consolidation between the fibres and the polymer matrix, with control of the fibre orientation and low cost [4, 5]. The aim of this work was to evaluate the mechanical properties of multidirectional 3D printed continuous carbon, glass and Kevlar fibre reinforced nylon composites, manufactured by FDM technique. Special attention was paid to the impact damage resistance and tolerance. [1] L. Nickels, Strengthening the 3D printing composites field, Reinforced Plastics, 62 (2018) 298-301 [2] L.G. Blok, M. L. Longana, H. Yu and B. K. S. Woods, An investigation into 3D printing of fibre reinforced Thermoplastic composites, Additive Manufacturing, 22 (2018) 176-186 [3] T. Liu, X. Tian, M. Zhang, D. Abliz, D. Li and G. Ziegmann, Interfacial performance and fracture patterns of 3D printed continuous carbon fibre with sizing reinforced PA6 composites, Composites Part A: Applied Science and Manufacturing, 114 (2018) 368-376 [4] R. Velu, F. Raspall and S. Singamneni, 3D printing technologies and composite materials for structural applications, Green Composites for Automotive Applications, chapter 8 (2019) 171-196 [5] Q. Hu, Y. Duan, H. Zhang, D. Liu, B. Yan and F. Peng, Manufacturing and 3D printing of continuous carbon fiber prepreg filament, 53 (2018) 1887-1989