Abstract
The most widely used 3D process, fused deposition modeling (FDM), has insufficient interlayer adhesion due to its layer-by-layer forming method. A support material is also essential for the hollow parts and cantilevers. Moreover, the polymer materials used have limited mechanical properties. These issues have restricted the application of FDM in high-performance fields. Continuous fiber-reinforced thermoplastic composites (CFRTPCs) have high mechanical properties and have recently become the focus of research in the field of 3D printing. This paper, using pipe parts as an example, proposes a hybrid of pure polymer (pure PLA used) and CFRTPC (flax fiber pre-impregnated filament) material to develop a printing method based on the outstanding mechanical properties of CFRTPC material. After studying the printing path planning algorithm, the CFRTPC filament is laid along the axial and radial directions on the surface of the polymer base to improve the printed parts’ properties. The method feasibility and algorithm accuracy are verified through the development of five-axis printing equipment with a double nozzle. Through the printed sample’s tensile, compression and bending tests, the results show that the tensile, compressive and bending properties of PLA pipe can be significantly enhanced by laying CFRTPC filament along the axial and radial directions of the pipe. To summarize, the introduction of CFRTPCs greatly improved the mechanical properties of the printed parts, and the implementation of our method provides an effective way to solve the defects of the FDM process.
Highlights
With increasing demands on product performance, high-performance plastics can meet the increased requirements, but fiber materials perform even better. People are turning their attention to composites in order to improve filament performance by adding fillers
Tekinalp et al [5] composited carbon fiber with Acrylonitrile Butadiene Styrene (ABS). They found that the tensile strength and tensile modulus of the fabricated test specimen increased by 115% and 700%, respectively, compared to traditional injection-molded composites
Tian et al [6,7] studied a combination of continuous carbon fiber and Polylactic acid (PLA), and the flexural strength and modules reached 335 MPa and 30 GPa
Summary
Polylactic acid (PLA) and Acrylonitrile Butadiene Styrene (ABS) are the most commonly used filaments in FDM because they are cheap, readily available and environmentally friendly. People are turning their attention to composites in order to improve filament performance by adding fillers. Tekinalp et al [5] composited carbon fiber with ABS. They found that the tensile strength and tensile modulus of the fabricated test specimen increased by 115% and 700%, respectively, compared to traditional injection-molded composites. Tian et al [6,7] studied a combination of continuous carbon fiber and PLA, and the flexural strength and modules reached 335 MPa and 30 GPa
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