A performance evaluation study of 3d printed nylon/glass fiber and nylon/carbon fiber composite materials

Abstract

3D printed fiber reinforced composites are replacing metals and thermosetting polymers due to their lightweight structure and mechanical performance. Fused deposition modeling (FDM) is an additive manufacturing technology that can produce complicated functioning parts. Samples of Nylforce composite materials were manufactured at three different raster orientations (0°, 45°, and 90°) with the help of a 3D printer. In order to evaluate the mechanical properties of the nylon composites with carbon fibers (CF) and glass fiber (GF); 3-point flexural tests were carried out. The highest stiffness (modulus) was found for nylon + GF composite at room temperature, indicating that the material can better resist bending forces. On the other hand, the nylon + CF composite exhibited elastic behavior, lower flexural strength, and higher deflection. Overall, the flexural strength of composites was improved because the interface between the nylon matrix and fibers provided good stress transfer. Dynamic mechanical analysis (DMA) also clearly indicated that the nylon + GF composite material had maximum storage modulus, loss modulus and complex modulus with low tan δ, indicating improved fiber/matrix interfacial interaction and limitation of polymer chain mobility. Moreover, scanning electron microscope (SEM) images revealed that the main drawbacks for nylon composite material were void formation, fiber pull-out, and fiber breakage. Generally, the results of this research provide a unique knowledge base regarding the structural behaviors and the mechanical properties of nylon composites built with 3D printing technology. Finally, the findings of the current research will be beneficial in the application of these composite materials in their end-use.