A novel method to combine fused deposition modelling and inkjet printing in manufacturing multifunctional parts for aerospace application

Abstract

Nowadays, the fabrication of smart product with sensing capability is still an arduous task due to the difficulties in integrating multifunctional materials using conventional method. To address this problem, this study presents a novel method to manufacture the multifunctional parts using fused deposition modeling (FDM) and inkjet printing (IJP) technologies. Firstly, the influence of process parameters on building time (BT), surface roughness (SR) and ultimate tensile strength (UTS) of poly-ether-ether-ketone (PEEK) samples manufactured by FDM was studied. Then, IJP was used to fabricate conductive lines on the surface of printed PEEK substrates. Finally, the process-structure–property relationship of PEEK parts before and after printing the conductive line was investigated. It is concluded that the BT and the SR of PEEK parts are significantly increased with an increased layer thickness, while the UTS increases steadily with an increase of nozzle temperature. Moreover, the maximum SR of 35.352 μm and the maximum UTS of 73.649 MPa are obtained at the infill angle of 45°. Furthermore, the warping deformation of PEEK samples will greatly affect SR during the real manufacturing, especially at both ends of the printed parts. Printed lines showing good aesthetic quality and the lowest electrical resistance (6.838 Ω/cm) are obtained on PEEK samples with the infill angle of 90°. This study demonstrates the possibility of manufacturing structure-integrated antenna by the combination of FDM and IJP processes.