Continuous Fiber Research Articles

A multi‐layer approach for additive manufacturing of continuous fiber composites

AbstractAdditive manufacturing (AM) of continuous fiber reinforced polymer composites (cFRPCs) requires innovative tool‐pathing strategies that account for the anisotropic properties of the continuous fibers and ensure their continuous deposition as reinforcement along the designed structure, reducing fibers bending and cutting. Existing 3D printing slicing software, designed for isotropic materials like neat polymers, has been adapted for 3D printing of continuous fiber composites, resulting in a layer‐by‐layer approach that necessitates filament cutting after each layer deposition. This method introduces discontinuities, weakening the material and underutilizing continuous fibers strength. In this research, we propose a novel tool‐pathing strategy designed to address these challenges through (1) Ensuring fiber continuity across layers by allowing overlapping filaments and (2) Strategically positioning fiber cut points based on stress distribution, modeled using finite element analysis. A Multi‐Layer Continuous Fiber Path (ML‐CFP) approach was introduced and validated on a simple bracket structure featuring two load‐application inserts. 3D printed brackets using different tool paths were tested to failure under tension and compression after compression molding to improve interlayer adhesion. Mechanical investigations confirmed that the ML‐CFP approach enhances fiber utilization, improving tensile strength and work to fracture by up to 46% and 100% through promoting failure in fibers rather than at cut points.Highlights Introduced the multi‐layer continuous fiber path method (ML‐CFP) in AM of cFRPCs. Introduced the strategic cut point placement (SCPP) based on stress distribution. Maintaining fiber continuity and reduce fiber bending by allowing filament overlap. Mechanical testing to compare the ML‐CFP with conventional slicing methods. Enhanced tensile strength by up to 46% and work to fracture by 100%.

Adjustment of Mechanical Properties of 3D Printed Continuous Carbon Fiber-Reinforced Thermoset Composites by Print Parameter Adjustments.

Reinforcing thermoset polymers with continuous carbon fiber (CF) tow has emerged as a promising avenue to overcome the thermal and mechanical performance limitations of 3D printed polymeric structures for load-bearing applications. Unlike traditional methods, manufacturing continuous fiber-reinforced composites by 3D printing has the unique capability of locally varying the mechanical properties of the composites. In this study, continuous CF thermoset composite specimens were printed with varying line spacing, resin flow rate, and nozzle sizes. The resin flow rates for different line spacings and nozzle sizes were optimized by topographic analysis. Printed composite mechanical properties were evaluated, and their trends were correlated with the trend of print parameter changes. Results showed that tensile strength and modulus could be altered and improved by ~50% by adjusting the printing process parameters. Higher composite strength and modulus were obtained by shortening the line spacing and nozzle diameter.

Additive manufacturing of continuous carbon fiber reinforced polymer composites using materials extrusion process. Mechanical properties, process parameters, fracture analysis, challenges, and future prospect. A review

Additive manufacturing of continuous carbon fiber reinforced polymer composites using materials extrusion process. Mechanical properties, process parameters, fracture analysis, challenges, and future prospect. A review

Detecting Multi-Scale Defects in Material Extrusion Additive Manufacturing of Fiber-Reinforced Thermoplastic Composites: A Review of Challenges and Advanced Non-Destructive Testing Techniques.

Additive manufacturing (AM) defects present significant challenges in fiber-reinforced thermoplastic composites (FRTPCs), directly impacting both their structural and non-structural performance. In structures produced through material extrusion-based AM, specifically fused filament fabrication (FFF), the layer-by-layer deposition can introduce defects such as porosity (up to 10-15% in some cases), delamination, voids, fiber misalignment, and incomplete fusion between layers. These defects compromise mechanical properties, leading to reduction of up to 30% in tensile strength and, in some cases, up to 20% in fatigue life, severely diminishing the composite's overall performance and structural integrity. Conventional non-destructive testing (NDT) techniques often struggle to detect such multi-scale defects efficiently, especially when resolution, penetration depth, or material heterogeneity pose challenges. This review critically examines manufacturing defects in FRTPCs, classifying FFF-induced defects based on morphology, location, and size. Advanced NDT techniques, such as micro-computed tomography (micro-CT), which is capable of detecting voids smaller than 10 µm, and structural health monitoring (SHM) systems integrated with self-sensing fibers, are discussed. The role of machine-learning (ML) algorithms in enhancing the sensitivity and reliability of NDT methods is also highlighted, showing that ML integration can improve defect detection by up to 25-30% compared to traditional NDT techniques. Finally, the potential of self-reporting FRTPCs, equipped with continuous fibers for real-time defect detection and in situ SHM, is investigated. By integrating ML-enhanced NDT with self-reporting FRTPCs, the accuracy and efficiency of defect detection can be significantly improved, fostering broader adoption of AM in aerospace applications by enabling the production of more reliable, defect-minimized FRTPC components.

Predictions of sheet molding compound composite structures using probabilistic finite element simulations with bimodal Weibull strength distributions

Due to the large scatters in Sheet Molding Compound (SMC) mechanical properties, the uncertainty in the prediction of mechanical responses of SMC composite structures is significantly high as compared to that for continuous fiber composite structures. Another challenge is the size effect resulting from the scatter in mechanical strengths, i.e., the measured material flexural strength is much higher than its tensile strength. As a result, classical approaches that rely on the mean tensile strength can substantially underpredict the flexural responses in Finite Element Analysis (FEA). This work investigates the use of a material model with bimodal Weibull distributions for its strength properties in Probabilistic FE (PFE) simulations. A Random Search-based optimization procedure was developed to obtain model parameters which are difficult to determine. The material model was verified by PFE simulations of standard experiments, and then examined in simulations of open-hole tension and disk bending tests.

One promising thermoplastic material: Poly(methyl methacrylate) and its continuous glass fiber reinforced composites by redox polymerization

AbstractRecently, thermosetting epoxy resin is expected to be substituted by thermoplastic featured from green circular economy. Poly(methyl methacrylate) (PMMA) has been well known as one promising thermoplastic resin, although its mechanical property needs to be further investigated. In this paper, the free radical polymerization of methyl methacrylate (MMA) was initiated by lauroyl peroxide/N,N‐dimethylaniline (LPO/DMA) and lauroyl peroxide/N,N‐dimethyl‐p‐toluidine (LPO/DMT) redox system at room temperature, respectively. The PMMA (n(MMA:LPO:DMA) = 200:1.2:1) exhibited excellent mechanical properties, and the tensile strength was 66.5 MPa, the bending strength was 118.0 MPa. The tensile strength increased to 78.9 MPa at −40°C, which suggested a promising application at low temperature. The resin was applied to fabricate continuous glass fiber reinforced PMMA (GF/PMMA) composites by vacuum‐assisted resin infusion. The 0° tensile strength and modulus were 1.17 and 43.7 GPa and 90° tensile strength and modulus were 48.3 MPa and 13.2 GPa, respectively. The mechanical properties of GF/PMMA composites are higher than GF/epoxy. Moreover, PMMA resin and glass fiber can be recycled from GF/PMMA composites by MMA as solvent, which is more energy‐efficient and environment‐friendly. This work is of great significance for preparing sustainable resin and composites.Highlights GF/PMMA composites were fabricated by vacuum perfusion. GF/PMMA composites showed higher mechanical properties than GF/epoxy. GF/PMMA composite was recycled with MMA and closed‐loop recovery was achieved.

Boosting machine learning algorithms for predicting the macroscopic material behavior of continuous fiber reinforced composite

Boosting machine learning algorithms for predicting the macroscopic material behavior of continuous fiber reinforced composite

Self-Repairable Carbon Fiber-Reinforced Epoxy Vitrimer Actuator with Multistimulus Responses and Programmable Morphing.

Smart shape-changing structures in aerospace applications are vulnerable to damage in harsh environments. Balancing high mechanical performance with self-repair capabilities poses a challenge due to inherent trade-offs between strength and flexibility. To address this challenge, an asymmetric bilayer-structured actuator was fabricated using commercially available continuous carbon fiber tows (CFs) as the passive layer and a dynamic cross-linked epoxy vitrimer as the active layer. The construction of the vitrimer-CF actuator involves a simple and scalable hot-pressing process, resulting in a tensile strength of 234 MPa and an interfacial bonding strength of 405 N·m-1. This actuator exhibits remarkable deformation capability (210°/7 s) and an efficient self-repair ability under various stimuli, including thermal (60-160 °C), light (0.4-1.0 W·cm-2), electric (2-4 V), and solvent (acetone). By adjustment of the orientation angle of CFs, complex left-handed and right-handed curling structures can be achieved. Leveraging the insights from photothermal/electrothermal actuation mechanisms, a quadruped crawling robot is developed capable of crawling 4 cm with a single light illumination. The actuator can lift objects 45 times its weight when subjected to light stimuli. Additionally, a flap actuator is constructed to achieve an angle change of 63° within 10 s under an electric stimulus, enabling remote control over the aircraft flight angle. These results demonstrate the potential of the vitrimer-CF actuator for advanced applications in intelligent aerospace structures.

Ultra-High Sensitivity Anisotropic Piezoelectric Sensors for Structural Health Monitoring and Robotic Perception

HighlightsA novel anisotropic sensor with oriented piezoelectric filaments was prepared, capable of detecting both the magnitude and direction of micro-deformations.Due to the efficient load transfer of continuous fibers and the formation of porous ferroelectrets, an ultra-low strain detection limit of 0.06% was achieved in the sensor.Given the sensor's ultra-low detection limit and deformation direction sensing capability, we developed the sensor for detecting micron-scale deformations in thin-film structures and for robotic tactile sensing applications.

A new path planning strategy driven by geometric features and tensile properties for 3D printing of continuous fiber reinforced thermoplastic composites

Three-dimensional (3D) printing technology for continuous fiber reinforced thermoplastic composites (C-FRTP), capable of rapid manufacturing of lightweight components with intricate geometric features, has emerged as one of the most promising technologies in the field of advanced composite manufacturing. Path planning is a crucial step for determining the fabrication quality of C-FRTP components. This study proposed a new 3D printing path planning strategy driven by the geometric features and tensile properties of C-FRTP components. The strategy employed the properties of the Euler graph to generate the continuous full-field filling paths, ensuring the geometric features of the target components. The intersections were scattered along the printing path to enhance the tensile strength. The feasibility and advantages of the new path planning strategy were validated by comparative experiments with different printing paths. The results indicated that the new strategy not only achieved the geometric features of the target components but significantly enhanced their tensile strength. Using the printing path generated by the new path planning strategy, the tensile strength of specimens featuring mounting holes reached 349.4 MPa, which was only about 4.1 % lower than the tensile strength of continuous fibers at straight paths. Compared to the existing contour-parallel path, the new strategy in this work improved the tensile properties by about 40.9 %. The new path planning strategy proposed in this study shows great potential to design and fabricate C-FRTP components with enhanced mechanical properties for practical applications.

Fine-Grain High-Performance Densified Oxide Fibers Produced by Open Ultrafast High-Temperature Sintering.

The considerable grain growth occurring during the long-term high-temperature sintering of polycrystalline oxide fibers negatively affects their mechanical properties, which highlights the need for alternative sintering methods. Herein, open ultrafast high-temperature sintering (OUHS) in air, characterized by rapid heating/cooling (>10000 K min-1) and a short high-temperature holding time (<10 s), is used to produce 3 mol% yttria-stabilized zirconia continuous fibers with coherent boundaries forming robust connections between fine grains. The tensile strength of these fibers (2.33GPa on average, sintering temperature = 1673 K) notably exceeds that of their counterparts produced by traditional sintering (1.17GPa). The effects of pores on fiber mechanicalproperties are analyzed using experimental and theoretical methods. For a versatility demonstration, OUHS is applied to several types of polycrystalline oxide fibers (HfO2, Al2O3, TiO2, Y2O3, and La2Zr2O7), considerably improving their mechanical properties and enabling crystalline phase control, which demonstrates the suitability of this procedure for the development of high-performance materials.

Design strategy for the prototyping of 3D-printed continuous fiber-reinforced components for solar-powered vehicle

Continuous fiber fused filament fabrication is an advanced 3D printing method that allows designers to produce high-performing lightweight structures, leading toward innovative design philosophies and sustainable production chains. In this work, we proposed a design strategy to manufacture selected components for a solar-powered vehicle, which consists of three stages. Firstly, the prototypes’ CAD models are developed, considering their geometric and manufacturing requirements. Then, a finite element analysis is carried out to ensure optimal fiber reinforcement of prototypes’ critical regions. Lastly, the manufacturing stage involves the slicing process and optimization of the time and cost of the printed part employing Markforged® technology. Adopting the proposed methodology, the experimental campaign investigated the print quality and performance of several prototypes of each component by adjusting printing parameters.

Experimental and numerical investigation of the damage propagation in regularly arrayed short fiber reinforced composite laminates under low‐velocity impact

AbstractThe outstanding mechanical performance and flowability of unidirectionally arrayed chopped strands (UACSs) give them an advantage in the manufacture of engineering structures with complex geometry. For the application of practical structures, the impact responses and damage evolution of material under low‐velocity impact must be investigated in advance. In this study, UACS laminates and continuous carbon fiber laminates with a stacking sequence of [0/90]4s and a thickness of 2 mm were fabricated for low‐velocity impact tests at 7, 11, 15, and 20 J. The impact responses and postimpact intralaminar damage area were analyzed according to the experimental results, including impact load responses and ultrasound C‐scan inspections. Moreover, to predict the damage evolution of the internal structure, the 3D finite element models were constructed in ABAQUS using a progressive damage model (PDM) through a user‐material subroutine VUMAT. Compared with continuous carbon fiber laminates, the dissipated energy of UACS laminates increases by approximately 10.64% and 57.37% for the 15 and 20 J, respectively. However, the intralaminar damage area of UACS laminates decreased by 29.96% and 28.16% at 15 and 20 J, respectively, since the discontinuous slits in UACS laminates can guide damage paths and suppress damage propagation.Highlights The regularly arrayed short fiber reinforced composite was studied. Revealed the low‐velocity impact responses and predicted the damage evolution. UACS and CFRP laminates have comparable impact performance. Illustrated the slits design can suppress the damage to a relatively small area.

A Comparative Study of Non-Destructive Testing Techniques: Active Thermography versus Shearography for 3D-Printed Thermoplastic Composites Reinforced with Continuous Carbon Fiber

This study investigates the feasibility and effectiveness of two non-destructive testing methods, active thermography and shearography, on 3D-printed thermoplastic (TP) composites reinforced with continuous carbon fiber. Artificial defects were introduced into the composite plate to benchmark the detection capabilities of these non-destructive testing techniques (NDT). Active thermography produced a thermogram that highlighted defects through variations in surface temperature. Although effective for identifying defects ranging from 3 to 10 mm in size at four different depths, specifically 1 mm, 1.25 mm, 1.5 mm, and 1.75 mm, through the thickness of a 2.8 mm plate, the method encountered some limitations. It faced challenges in detecting deeper defects and accurately determining their shapes. Shearography, which utilizes fringe pattern distortions to detect surface displacement anomalies, successfully identified near-surface defects within the same size range. However, it required more expertise for accurate interpretation and struggled with detecting smaller and deeper defects. The complementary strengths and limitations of these methods suggest that employing both could offer a more comprehensive solution for defect detection in 3D-printed TP composites.

Experimental investigation of high-velocity impact response and compression after impact behavior of continuous carbon fiber thermoplastic composites

In order to meet the urgent needs for the application of thermoplastic composite structures in aircraft manufacturing and other fields, the impact resistance and damage tolerance of continuous carbon fiber reinforced thermoplastic composite laminates (CCFRTP) are investigated by high-velocity impact (HVI) and compression after impact (CAI) experiments in this paper. The impact experiment results show that the ballistic response of laminates under small-angle conventional impact is similar, and the impact resistance of laminates under large-angle oblique impact is significantly improved. The failure mechanism of laminates under high-velocity impact is revealed by analyzing the impact process of the projectile, the energy absorption level, the failure morphology and internal damage degree of laminates comprehensively. It is clear that the impact angle and velocity of the projectile will significantly affect the coupling form of the failure mechanism and lead to differentiated results. The results of in-plane compression experiment of laminates with impact damage show that the bearing capacity of laminates is significantly weakened by high velocity impact damage, and the residual strength of laminates is directly determined by the mode and degree of impact damage. In particular, through the analysis of the energy absorption mechanism, a trend prediction model of ballistic limit value with impact angle is established, and the influence of high-velocity impact damage on the residual strength of laminates is revealed. This study provides a better understanding of the mechanical response of thermoplastic composite structures to high-velocity impact loads.

Development of the forming limit diagram for fiber-reinforced thermoplastic composites and its temperature effect

The aim of this study is to investigate the formability properties of thermoplastic composite sheets and to develop a forming limit diagram (FLD) for them under ambient and elevated temperatures. Polypropylene thermoplastic composite sheets reinforced with unidirectional continuous glass fibers in a four-layer 0–90 layup were used in this research. Experimental findings demonstrate that the failure of samples at room temperature is more similar to brittle failure and occurs suddenly, whereas at elevated temperatures, the failure resembles ductile failure and occurs gradually. Employing the Nakajima method, a forming limit diagram for the composite material was successfully established at both ambient and elevated temperatures. The resultant forming limit diagrams illustrate an augmented strain tolerance of the material at elevated temperatures. Notably, despite the increased depth of stretch observed at elevated temperatures in comparison to ambient conditions, a concomitant reduction in the force requisite to induce deformation is evident.

Fibre Medullation Characteristics in Peruvian Llamas (Lama glama)

Background: The textile use of llama fiber, achieved through genetic improvement, llama selection and management, shows great potential for producing high-quality clothing and fabrics; providing an alternative income to highland residents who raise llamas. The aim of this research was to determine the fiber medullation of white Ch´aku and Q´ara color varieties of Llamas (Lama glama) from the communities of the Macusani district, Puno Peru. Methods: A total of 88 Llamas from the Ch´aku and Q´ara white color varieties, including males and females, from the age of milk teeth and two teeth, were used. Fiber samples of approximately 10 g were taken from the thigh, middle rib and shoulder, totaling 264 samples. Samples were analyzed at the Fiber Laboratory of the District Municipality of Corani, using the FIBER MED equipment. Data were analyzed in a completely randomized design (CRD) with a 2(variety) × 2 (sex) × 2 (age group) × 3 (body area) factorial arrangement. Result: The percentage of fiber medullation types in Ch´aku and Q´ara Llamas averaged 46.02% and 47.38%, showing no significant difference (p greater than 0.05). In Ch´aku Llamas, a statistical difference was observed by sex (p less than 0.05) for the percentage of medullated, non-medullated and continuous fibers in males and females. In Q´ara variety, there was a significant difference in the percentage of medullated, non-medullated and continuous fibers between milk teeth and two teeth age groups. There was no significant difference (p greater than 0.05) between body area samples.

Design optimization of automotive carbon fiber composite material floor laminate based on PSO-BFO algorithm

In response to the current challenges of low precision and efficiency in the optimization of composite material layups, the insufficient lightweight of automotive body floors, and the high cost of carbon fiber composites, this study introduces an optimized design method for carbon fiber composite flooring layups. Based on implicit parametric technology, a hybrid PSO-BFO (Particle Swarm Optimization-Bacterial Foraging Optimization) algorithm is employed. This approach achieves an integrated optimization of materials, processes, and structures, thereby balancing and reducing costs. The SFE-CONCEPT is utilized to establish an implicit parameterization model for the body floor, which is validated through experiments and finite element simulation analysis. Concept design and modeling of the carbon fiber composite material floor laminate are performed. Continuous variable optimization is employed to determine the thickness, tile shape, and number of layers for the front, middle, and rear floors. A continuous variable discretization rounding strategy is used to obtain the discrete layer numbers for each laminate orientation of the composite material floor. The continuous fiber lamination strategy is applied to create different shared lamination regions. The PSO-BFO hybrid optimization method is proposed to optimize the lamination sequence as a multi-objective optimization, addressing the challenges of discrete lamination sequence, explosive combinations, and multiple variables in the optimization design of carbon fiber composite material floor laminates. The optimization results demonstrate improvements of 34.4% in floor quality M, 6.0% in static bending stiffness BS, and 5.3% in lightweight coefficient QLX using the proposed PSO-BFO method. PSO-BFO and PSO-GA (Particle Swarm Optimization-Genetic Algorithm) methods are more capable of obtaining global optimal solutions for complex optimization problems than single optimization algorithms. Still, the results obtained by the PSO-BFO method are more balanced.

Three-Dimensional Printing Limitations of Polymers Reinforced with Continuous Stainless Steel Fibres and Curvature Stiffness

This study investigates the printability limitations of 3D-printed continuous 316L stainless steel fibre-reinforced polymer composites obtained using the Materials Extrusion (MEX) technique. The objective was to better understand the geometric printing limitations of composites fabricated using continuous steel fibres, based on a combination of bending stiffness testing and piezoresistive property studies. The 0.5 mm composite filaments used in this study were obtained by co-extruding polylactic acid (PLA), with a 316 L stainless steel fibre (SSF) bundle. The composite printability limitations were evaluated by the printing of a series of ’teardrop’ shaped geometries with angles in the range from 5° to 90° and radii between 2 and 20 mm. The morphology and dimensional measurements of the resulting PLA-SSF prints were evaluated using μCT scanning, optical microscopy, and calliper measurements. Sample sets were compared and statistically examined to evaluate the repeatability, turning ability, and geometrical print limitations, along with dimensional fluctuations between designed and as-printed structures. Comparisons of the curvature bending stiffness were made with the PLA-only polymer and with 3D-printed nylon-reinforced short and long carbon fibre composites. It was demonstrated that the stainless steel composites exhibited an increase in bending stiffness at smaller radii. The change in piezoresistance response of the PLA-SSF with load applied during the curvature bending stiffness testing demonstrated that the 3D-printed composites may have the potential for use as structural health monitoring sensors.

Preparation of continuous carbon fiber reinforced PA6 prepreg filaments with high fiber volume fraction

High-performance continuous carbon fiber prepreg filaments have been a research hotspot in the field of additive manufacturing in recent years, and are considered to be an effective option for improving the mechanical strength of thermoplastic composite parts. However, the effect of fiber volume fraction on the microstructure and tensile properties of 3D printed prepreg filaments remains miss. Therefore, this study selected suitable impregnation processes and materials to prepare prepreg filaments with different fiber volume fraction and investigated their mechanical properties and microscopic morphologies. The results show that the increase of fiber volume fraction effectively promoted the interface bonding between fiber and resin, and increased capacity for load transfer. When the fiber volume fraction was 54.0 %, the tensile strength of the prepreg filaments and specimens reached 1977 MPa and 334 MPa, respectively. This study can provide a process optimization strategy for the preparation of more types of continuous fiber prepreg filaments with high fiber volume fraction, as well as a data reference for the preparation of high-performance 3D-printed thermoplastic composites.