Fabrication of Cellular Composite Structures with Continuous Fiber Reinforcement and Different Infill Patterns Using Fused Filament Fabrication

Abstract

Additive manufacturing (AM), also known as 3D printing, is a process of creating three-dimensional objects with complex geometries that is utilized in various engineering applications. Continuous carbon fiber (CCF) is a high-performance material that offers a range of benefits in terms of strength, weight, and durability. Fused filament fabrication (FFF) is a type of AM that uses a thermoplastic filament as a material with which to create a three-dimensional object, and it has been widely used in various applications, as it enables the faster, cheaper, and more customizable production of parts and products. Lightweight cellular composite structures consists of small, repeating unit cells that are interconnected to form a larger structure, and they are employed in high engineering applications. In this study, cellular composite structures were fabricated using FFF technology, considering two types of infill paths design (grid and triangular) manufactured at three infill density levels (20%, 40%, and 60%). After the fabrication process, tensile and flexural properties were experimentally investigated, and the influence of the infill pattern and density on the cellular composite parts were studied. The achieved results demonstrated that the infill design pattern and its density had great influence on the mechanical properties of the cellular structure. The obtained results also showed that the lightweight cellular composite parts had great potential for use in structural applications.