Composite Parts Research Articles

Experimental Method to Determine the Draping Behavior of Auxiliary Materials for the Vacuum Bagging of CFRP Parts on Doubled-Curved Surfaces

The production costs of aircraft primary structures made of carbon fibre reinforced polymer (CFRP) are significantly higher than for comparable metal-based structures. Today substantial effort is made to achieve a sufficient reproducibility and parts’ quality in manufacturing processes of CFRP structures. Especially the sub process vacuum bagging for infusion processes is still expensive. One of the reasons is the complex positioning of the flexible auxiliary materials which have to be stacked on the preform. During the positioning on doubled-curved surfaces these materials tend to form wrinkles, which can lead to defects of the composite part. Yet, a defined description of the wrinkling behavior of the auxiliary materials on doubled-curved surfaces does not exist. In this work a characterization of the wrinkling behavior on doubled-curved surfaces is investigated for the auxiliary materials of the Vacuum Assisted infusion Process (VAP®): release film, perforated peel ply, flow media, membrane and vacuum foil. Therefore, an experimental test method is derived similar to established hemisphere deformation test methods. The wrinkling behavior for the specific VAP auxiliary materials is empirically determined on differently curved surface geometries. It is shown that the draping behavior can be characterized by partial wrinkle-free surfaces between the wrinkles. A material specific threshold is derived to determine the appearance of wrinkles. The work shows that a characterization of the draping behavior of auxiliary materials on doubled-curved surfaces is possible. With the gained knowledge the potential for an increase of the vacuum bagging reproducibility is given.

Impact of Rheology-Based Optimum Parameters on Enhancing the Mechanical Properties and Fatigue of Additively Manufactured Acrylonitrile-Butadiene-Styrene/Graphene Nanoplatelet Composites.

This study investigates the interaction between static and fatigue strength and the rheological properties of acrylonitrile-butadiene-styrene (ABS) polymer reinforced with graphene nanoplatelets (GNPs) in both filament and 3D-printed forms. Specifically focusing on the effects of 1.0 wt.% GNPs, the study examines their influence on static/fatigue responses. The rheological behaviour of pure ABS polymer and ABS/GNPs nanocomposite samples, fabricated through material extrusion, is evaluated. The results indicated that the addition of 1.0 wt.% GNPs to the ABS matrix improved the elastic modulus of the nanocomposite filaments by up to about 34%, while reducing their ductility by approximately 60%. Observations revealed that the static and fatigue responses of the composite filament materials and 3D-printed parts were not solely attributed to differences in mechanical properties, but were also influenced by extrusion-related process parameters. The shark-skin effect, directly related to the material's rheological properties, had a major impact on static strength and fatigue life. The proposed method involved adjusting the temperature of the heating zones of the extruder during filament production to enhance the static response of the filament and using a higher nozzle temperature (270 °C) to improve the fatigue life of the 3D-printed samples. The findings reveal that the proposed parameter optimisation led to filaments with minimised shark-skin effects, resulting in an improvement in ultimate tensile strength compared to pure ABS. Moreover, the 3D-printed samples produced with a higher nozzle temperature exhibited increased fatigue lives compared to those manufactured under identical conditions as pure ABS.

Mechanical properties enhancement of 3D-printed HA-PLA composites using ultrasonic vibration assistance

ABSTRACT 3D-printed HA-PLA composites have attracted much attention because of their excellent biodegradability and osteointegration properties. However, HA particles negatively affect the mechanical properties of the composite parts. In this study, ultrasonic vibration-assisted 3D printing was used to improve the mechanical properties of HA-PLA composite specimens, and the effects of different infill angles and ultrasonic vibration power on the mechanical properties were investigated. The results demonstrated that the degradation and anisotropy of the mechanical properties of HA-PLA composites were alleviated by the use of ultrasonic vibration. By applying the ultrasonic vibration, the tensile and flexural strengths of the 20 wt% HA-PLA specimens fabricated with a 90° infill angle demonstrated the largest improvement of 104.3% and 112.7%, respectively. The high-frequency ultrasonic vibration waves promoted the spreading and fusion of the extruded materials, thereby reducing overlapping voids within the specimens and improving the interface bonding strength, also facilitated the refinement and dispersibility of the HA particles, which inhibited the formation of stress concentrations within the specimens and ultimately improved the mechanical properties. The printing process developed in this study can also be adapted to other particle (or other reinforcement types) reinforced composite to improve their mechanical performance.

The microstructures and mechanical properties of the TC4 titanium alloy fabricated by laser composite manufacturing technology

The effective combination of traditional forging and laser three-dimensional forming technology can play a crucial role in the preparation of large metal part with fine structures, thereby accelerating the manufacturing cycle of parts and reducing costs. This study used laser composite manufacturing technology to perform complete annealing heat treatment on TC4 titanium alloy structural part produced from traditional forgings. The analysis of microscopic structure, chemical composition, and mechanical properties has verified that the overall mechanical properties consistency of the composite manufacturing part has been effectively improved. The results indicate that laser composite manufacturing part have good metallurgical bonding, and there is no component segregation phenomenon in the composite manufacturing area. After complete annealing, the α lath in the composite manufacturing part is coarsened, the strength of the laser forming area is reduced, and the consistency of mechanical properties of the forging area and the laser forming area is enhanced. The consistency of strength of the two areas is increased from 78% before heat treatment to 84%.

Monitoring of the heating rate of a motorized gear system using UV-curable resin containing Y2WO6:Yb3+-Er3+ up-converting nanoparticles as optical temperature sensor

The ability to create various three-dimensional objects and precisely deposited layers has enabled manufacturers using UV-curable resins to produce customized and complex composite parts with greater efficiency and precision. There are many products used in this photo-induced solidification process, and one of them is a mixture of organic compounds forming a resin, which is cured using ultraviolet light to achieve the desired final hardness. In addition, the combination of this resin with innovative materials has led to the creation of interesting elements with a wide variety of applications. For this reason, this work describes the implementation of lanthanide-based luminescent nanoparticles Y2WO6 doped with Yb3+ and Er3+ and admixed in a resin, for deposition on a metallic gear surface via painting and UV curing. The as-prepared luminescent gears start to generate heat due to the occurrence of mechanical friction when they start to work. Analyzing the ratio between the thermalized Er3+ emissions at 525 nm (2H11/2 → 4I15/2) and 550 nm (4S3/2 → 4I15/2) we could remotely detect small temperature variations that gears undergo through friction. This technique is especially useful in monitoring temperature in elements where measurements with thermographic cameras or with direct contact is inaccurate or is not possible. This work can open new horizons in monitoring of heat flow in various scientific and industrial processes, utilizing the benefits of non-invasive temperature detection via luminescence thermometry technique.

Investigation of recovery behavior on 3D-printed continuous plant fiber-reinforced composites

The mechanical properties and accuracy of 3D-printed composites can be significantly affected by printing parameters. This work discovered a noteworthy recovery phenomenon during 3D printing of continuous flax fiber-reinforced composites (CFFRCs). The yarn count and printing speed are the critical factors that influence the recovery behavior, which, in turn, affects the thickness, the fiber volume fraction, and the void content of CFFRCs, ultimately impacting the mechanical properties. Smaller yarn counts have a greater effect on the recovery behavior of CFFRCs. Increasing the printing speed from 5 mm/s to 15 mm/s leads to the loss of tensile properties and flexural modulus in CFFRCs up to 30 % and 58 %, respectively. The recovery mechanism of the CFFRCs is further elucidated with the observation of temperature distribution during the printing process. This indicates that recovery is more likely to occur in the compressed yarn with a twisted structure when the deposited thermoplastic matrix exceeds the glass transition temperature. The results and findings have the potential to enhance the process optimization of 3D-printed continuous plant fiber composite parts, ensuring high mechanical properties and dimensional precision.

Additive manufacturing of AA5083/TiN-Diamond hybrid nanocomposite parts via additive friction stir deposition: Metallurgical structure, mechanical, tribological, and electrochemical properties

Nano-diamond (ND) is a special ultrafine reinforcement whose agglomeration properties and weak interfacial bonding limit its application in aluminum matrix composites. This study used the additive friction stir deposition (AFSD) technique to produce AA5083-H321/2.5 wt% nano TiN/ND additive manufacturing deposition hybrid composite parts (AMDCPs) and a non-composite part (AMDNCP) was also deposited for comparative analysis. The aim was to improve the microstructure and examine the effect of the deposition process parameters, which include 900, 1250, and 1600 rpm rod rotation speed and 5 and 12 mm/min feed rate. The AFSD process parameters were used to calculate the heat input. The consumable rod and AMD parts were evaluated for their macrostructure, microstructure, macro-hardness, tribological, and corrosion properties. The microstructural features were examined using an OM, XRD, and SEM equipped with an EDS. The worn and corrosion surface morphology was investigated using SEM, and hardness was also evaluated as contour maps. The results show that defect-free deposited multilayer AA5083-nano TiN/ND hybrid composite parts were successfully manufactured, and analysis revealed a lower D/H ratio, well-bonded layers, homogeneously distributed TiN/ND and fragmented IMC components, and equiaxed refined grain microstructures. The deposited composites via AFSD showed a lower corrosion rate, higher hardness, and wear resistance than the deposited AA5083 consumable rod and AMDNCP. The AMDP C900-12 demonstrates an optimized deposition process parameter (900 rpm, 12 mm/min) with superior properties, including an increase in hardness by 9.3%, a reduction in grain size by 54%, and a decrease in corrosion rate by 45.2% related to the AMDNC part.

Investigation of the effects of volume fraction, aspect ratio and type of fibres on the mechanical properties of short fibre reinforced 3D printed composite materials

AbstractMechanical behaviour of 3D-printed composite parts is affected by the volume fraction, aspect ratio and type of fibre reinforcement. Although in the literature experimental approaches have been used to characterise the effects of the above factors on the mechanical properties of 3D printed parts, time and cost of the manufacturing process as well as the uncertainty associated with a large number of experimental techniques are the key issues. This study aims to address these challenges by developing a methodology based on a multi-scale Finite Element (FE) analysis of representative volume element (RVE) of 3D printed composite parts to predict the effective orthotropic properties. To account for the effects of fibre features, RVEs were modelled considering variables of volume fraction, aspect ratios and type of short fibres. To study the main and interaction effects of the above variables on the mechanical properties of 3D printed composite parts, a structured approach based on the Design of Experiments is used. The FE stress analysis of the RVE provides an understanding about the potential failure modes such as interfacial debonding between fibres and matrix, interlayer and intralayer delamination that may occur in load-bearing 3D printed composite parts. The FE computed mechanical properties are validated against experimental data through a series of mechanical testing of flexure, Iosipescu, and short beam shear which were conducted in conjunction with the Digital Image Correlation technique. As a result, certainty is obtained in using the proposed approach for a fast iterative design of 3D printed composite parts prior to industrial applications.

Experimental substantiation of the technology for manufacturing composite parts based on a viscous metal-polymer

ABSTRACT The article deals with an experimental study of the technological process of obtaining a composite ABS, a metal-polymer part. As the title implies the article describes a method and device for the manufacture of composite parts based on the method of vacuum suction of a viscous metal-polymer into a shell form. Recommendations are given on the technological modes of filling the mould, taking into account the presence of vibration in the process of filling the mould with a metal-polymer, as well as the Reynolds number parameter for establishing a laminar flow of the metal-polymer in the technological mould cavities. The study of the strength of the designed composite part has been carried out using the finite element method of the APM FEM module. The calculations of the strength and stiffness of parts made of ABS, metal-polymer and metal make it possible to compare the strength characteristics of parts made by various methods. Relevant recommendations are given on the use of a composite part reinforced with a metal-polymer in the field of mechanical engineering.

Inter-bead void reduction by crossing printing routes of fused filament fabricated composites

PurposeThe use of continuous fiber-reinforced filaments improves the mechanical properties obtained with the fused filament fabrication (FFF) process. Yet, there is a lack of simulation tailored tools to assist in the design for additive manufacturing of continuous fiber composites. To build such models, a precise elastic model is required. As the porosity caused by interbead voids remains an important flaw of the process, this paper aims to build an elastic model integrating this aspect.Design/methodology/approachTo study the amount of porosity, which could be a failure initiator, this study proposes a two step periodic homogenization method. The first step concerns the microscopic scale with a unit cell made of fiber and matrix. The second step is at the mesoscopic scale and combines the elastic material of the first step with the interbead voids. The void content has been set as a parameter of the model. The material models predicted with the periodic homogenization were compared with experimental results.FindingsThe comparison between periodic homogenization results and tensile test results shows a fair agreement between the experimental results and that of the numerical simulation, whatever the fibers’ orientations are. Moreover, a void content reduction has been observed by increasing the crossing angle from one layer to another. An empiric law giving the porosity according to this crossing angle was created. The model and the law can be further used for design evaluation and optimization of continuous fiber-reinforced FFF.Originality/valueA new elastic model considering interbead voids and its variation with the crossing angle of the fibers has been built. It can be used in simulation tools to design high performance fused filament fabricated composite parts.

Simultaneous port number and location optimization of mold gates‐vents using in‐house coded stochastic multi‐objective optimization algorithm

AbstractThis research introduces multi‐objective stochastic optimization (MOSO) and non‐dominated sorting differential evolution (NSDE) in‐house coded algorithms for enhancing the optimization of the resin transfer molding (RTM) process during the mold‐fill phase for composite parts. Glass fiber‐vinyl ester‐based automotive bonnet and carbon fiber‐RTM6‐based aircraft wing flap parts were used as the case studies. Initially, the NSDE algorithm was developed for the simultaneous optimization of dry‐spot content and mold‐fill time by changing the locations of gates and vents with pre‐fixed port numbers. Then, the MOSO algorithm was designed for the concurrent optimization of the dry‐spot content, mold‐fill time and total number of ports by changing both the numbers and locations of gates and vents. The effect of race‐tracking was also investigated using higher permeability values at the composite part‐cut edges. When compared, the MOSO algorithm predicted less dry‐spot content, number of ports, mold‐fill time and uniform resin flow‐front progressions with lesser functional evaluations and computational time than the NSDE algorithm.Highlights The non‐dominated sorting differential evolution (NSDE) and multi‐objective stochastic optimization (MOSO) algorithms were developed for the optimization of the mold fill phase of resin transfer molded composite parts. The development of the NSDE algorithm aimed to concurrently optimize the dry‐spot content and mold‐fill time by changing the locations of gates and vents with pre‐fixed port numbers. The MOSO algorithm was designed to concurrently optimize dry‐spot content, mold‐fill time, and the total number of ports by varying both the numbers and locations of gates and vents. The MOSO algorithm predicted better‐automated mold‐fill phase optimalities for the resin transfer molded composite parts compared to the NSDE algorithm.

Concave and convex small radius bending behavior of single and multiple layers reinforcement fabrics

Multilayer reinforcement fabrics are increasingly used for manufacturing structural polymer composites. In liquid molding processes, dry reinforcement fabrics are draped on a mold first, and infused with a liquid resin such as an epoxy in a subsequent manufacturing step. This presents major advantages in terms of operational flexibility and costs. However, draping multilayer reinforcement fabrics on complex mold geometries is challenging. Small radius mold corners constitute a major manufacturing challenge as they lead to variability in dry fabric positioning and resin-rich corners in polymer composite parts. Spring-back of fabrics bent over or into single curvature mold corners is a widespread industrial concern. However, contrary to draping over double-curvature surfaces, bending spring-back from convex or concave single-curvature corners has received very limited attention. No testing method is available. This paper quantifies reinforcement fabric bending spring-back. Single and multiple layer stacks were bent along three directions over convex and into concave 90° corners with five radii spanning 1.59 mm to 12.70 mm. In all cases, five replicated tests enabled variability quantification. Fabric stacks were also quantified using cantilevered bending tests for comparison purposes. Mold radius was found to affect the behavior to a larger extent than testing direction, number of layers or use of a binder.

ВПЛИВ РУДНОВУГІЛЬНИХ КОМПОЗИЦІЙ У СКЛАДІ ШИХТИ НА ФОРМУВАННЯ ТЕРМІЧНО РЕЗЕРВНОЇ ЗОНИ ДОМЕННОЇ ПЕЧІ

The object of research is the technology of iron smelting when using ore-coal compositions. The purpose of the work is the effect of changing the composition of the blast furnace charge on the thermal state of the formation of the thermal reserve zone. Research methods - theoretical studies are based on the basic principles of physical chemistry and the theory of metallurgical processes. Experimental studies were carried out in laboratory and industrial conditions. Scientific novelty - there is a "coupling phenomenon" between recovery and gasification - this is a close contact between small particles of iron oxides and carbon, which is formed in the ore-coal composite, which ensures an increase in the efficiency of blast furnace smelting. Reduction of fuel consumption and, accordingly, the amount of gases per unit charge of modern blast furnace smelting, the height of the reserve zone is reduced; this zone is not observed in the vertical elements of the furnace with the maximum ore load. Practical significance - the use of ore-coal composites provides a high speed of iron recovery and carbon gasification reactions and a low initial temperature of carbon gasification of 250-420ºС, which is ensured by gas recirculation in the under burden, due to the short distance between the parts of iron-containing and carbon composites and their sizes, where the distance between them is short and the limit of the reaction is "visible" to both.

Progressive failure simulation of angled composite beams subject to flexural loading

Laminated composite structures, while offering weight savings compared with their metal counterparts, are susceptible to ply separation, (i.e., delamination mode of failure) due to the lack of through-thickness fiber reinforcements. In this paper, numerical simulations are used to gain an enhanced understanding of angled composite beam delamination when subjected to four-point bending consistent with the ASTM D-6415 test standard, with an expectation that the learning gained from this work is extensible to laminated composite components in general. While illustrating mesh sensitivity, manufacturing and frictional effects, four items of interest are examined: (1) the undamaged state/pre-peak load response, (2) the through-thickness peak tensile capability, (3) the post-peak load drop, and (4) the subsequent post-peak damaged response. A Finite Element Analysis (FEA) model is developed that incorporates the Smeared Crack Approach (SCA) to capture progressive failure modes within the element formulations directly, effectively eliminating the need for a priori specification of discrete delamination zones. The ability to incorporate failure directly within the element structure is particularly notable where laminates may not realistically permit a high number of interface layers or where geometry may be complex. Leveraging experimental data of curved composite laminates subject to four-point bending, the proposed approach successfully predicts the correct behavior throughout the damage progression. Additionally, this study offers an insight into effects of manufacturing-induced imperfections and frictions between the specimen and fixture on the prediction of inter-laminar strength of a curved composite part.

Towards Advancing Translators’ Guidance for Organisations Tackling Innovation Challenges in Manufacturing within an Industry 5.0 Context

Following the vision of the European Commission, organisations and workers establishing Industry 5.0 approaches aspire to more future-proof, resilient, sustainable, and human-centred European industries. In this contribution, we explore how technological innovations that contribute to a “win–win” interaction with involved stakeholders may be advanced in a human-centred and transparent proceeding supported by impartial expert translators who provide information or knowledge-based guidance for decision-makers, initiators and implementers in manufacturing innovation driven by sustainability. We elaborate a stepwise procedure for agreeing on milestones and conjointly treading the path towards solving innovation challenges during a translation process. We exemplify the technological aspects of such a process using an innovation case aiming at identifying parameters for enhancements in a vacuum-bagging process applied to the manufacturing of composite parts from prepregs based on condensation-curing matrix resins made from renewable resources. In detail, we present a straightforward design of an experimental approach varying the dwelling temperature and the temperature ramps during the curing of stacked prepregs. In this way, we demonstrate that for cured composites comprising a poly(furfuryl alcohol)-based matrix, the porosity and connected mechanical properties achieved with autoclave-free curing processes sensitively depend on these process parameters. Applying the resulting data-based model is shown to support decision-making for sustainable composite manufacture.

Continuous tow shearing for the automated manufacture of defect-free complex 3D geometry composite parts

It has always been challenging to manufacture a composite structure with complex geometry using automated fibre placement (AFP) process. The tool surface is difficult to be tessellated using fibre tapes with a finite width, without producing gaps and overlaps, and fibre steering along non-geodesic fibre paths produces various defects such as tape buckling and pull-up. In this work, a defect-free fibre-steering process on a complex surface was demonstrated by realising the continuous tow shearing (CTS) process in three dimensions. A new head control algorithm was developed, which defines the head orientations and trajectories based on the pin-jointed net model to manipulate the fibre tow using both in-plane shear and out-of-plane twisting deformations. Fibre steering process utilising this new algorithm was tested on a doubly-curved surface, using an industrial robot arm equipped with a CTS prototype head, and its layup quality and accuracy were assessed by using a three-dimensional laser profile scanner. An experimental comparison with the conventional AFP process showed that the new control algorithm enables defect-free fibre steering on complex 3D surfaces allowing for simplifying the design and analysis of novel composite structures.

Box-Behnken modeling to optimize the engineering response and the energy expenditure in material extrusion additive manufacturing of short carbon fiber reinforced polyamide 6

The field of production engineering is constantly attempting to be distinguished for promoting sustainability, energy efficiency, cost-effectiveness, and prudent material consumption. In this study, three control parameters (3D printing settings), namely nozzle temperature, travel speed, and layer height (LH) are being investigated on polyamide 6/carbon fiber (15 wt%) tensile specimens. The aim is the optimum combination of energy efficiency and mechanical performance of the specimens. For the analysis of the results, the Box-Behnken design-of-experiment was applied along with the analysis of variance. The statistical analysis conducted based on the experimental results, indicated the importance of the LH control setting, as to affecting the mechanical strength. In particular, the best tensile strength value (σB = 83.52 MPa) came from the 0.1 mm LH. The same LH, whereas caused the highest energy consumption in 3D printing (EPC = 0.252 MJ) and printing time (PT = 2272 s). The lowest energy consumption (EPC = 0.036 MJ) and printing time (PT = 330 s) were found at 0.3 mm LH. Scanning electron microscopy was employed as a part of the manufactured specimens’ 3D printing quality evaluation, while Thermogravimetric analysis was also conducted. The modeling approach led to the formation of equations for the prediction of critical metrics related to energy consumption and the mechanical performance of composite parts built with the MEX 3D printing method. These equations proved their reliability through a confirmation run, which showed that they can safely be applied, within specific boundaries, in real-life applications.Graphical abstract

Метод чисельного визначення динамічних характеристик лопаті повітряного гвинта з композиційного матеріалу

The subject matter of this article is the dynamic characteristics of a composite propeller blade. Determination of the modes and frequencies of natural vibrations is necessary to predict the dangerous resonance modes of aircraft engines and to identify the most stressed local zones of the blade surface. The goal of this study is to develop a verified method for determining the dynamic characteristics of composite rotor parts of aircraft engines based on the known properties of the structural components of the composite material. A general mathematical statement of the problem of elasticity theory for the analysis of the dynamic characteristics of composite structures is described. A complete system of equations that describes the mechanical state of the body within the framework of the continuum mechanics approach was developed. Geometric modeling of the propeller blades was performed. Modeling and numerical investigation of the natural frequencies and mode shapes of the propeller blade were performed using the finite element method using the ANSYS software package. Based on the results of numerical research of the stressed and deformed state of the propeller blade, the first five natural vibration frequencies and the distribution of the local stress field were determined. The most stressed local zones on the blade surface were determined for each form of natural vibration. The propeller blade model was verified using an experimental study of the first five forms and frequencies of natural blade vibrations. The eigenfrequencies of the blade vibration were experimentally determined using the method of free (natural) vibrations. The resonance method was used to experimentally determine the resonant frequencies and vibration modes of the blade. The distribution of the blade deformation field was investigated using the strain gauge method. The highest error in the verification of numerical and experimental research is 4.11% for the fourth vibration frequency. Conclusions. The scientific novelty of the results obtained is that the effective elastic properties of the composite material for calculations should be determined using the procedure of numerical homogenisation of composite materials of different reinforcement structures by the properties of the matrix and fibers. The method does not require experimental determination of the effective elastic constants for the layers of blade components of different weave architecture patterns.

Rapid prediction of the cure-induced distortion of newly developed composite parts via transfer learning

Accurately predicting Cure-Induced Distortion (CID) is paramount to ensuring manufacturing precision. Existing prediction models heavily rely on material parameters associated with the CID, which presents challenges for newly developed composites due to the time-consuming, expensive, and limited accuracy of parameter characterization processes. With recognizing the shared curing mechanism across various composites, this paper introduces a transfer learning-based approach that leverages a small dataset of practical CID data from the newly developed composite and historical knowledge from existing composites to achieve rapid and accurate CID predictions. This approach was validated for two typical CID prediction cases by implementing a transfer learning framework, and various sampling methods were explored to assess the stability and repeatability of prediction results. The results indicate that the proposed method can predict the CID within a 5% margin of error. This paper offers a promising approach for predicting CID in the design and manufacturing processes.

Study of 3D-printed onyx parts reinforced with continuous glass fibers: Focus on mechanical characterization, analytical prediction and numerical simulation

The 3D printing of continuous-fiber composites is currently relevant to engineers and researchers. This study aims to characterize and predict the mechanical properties of Onyx/glass fiber specimens printed using 3D printing. The work assesses the impact of glass fiber printing parameters on the mechanical behavior of printed parts and proposes analytical and numerical methods to predict mechanical properties. A physicochemical analysis was conducted on 3D printed continuous glass fibers. The study also investigated the impact of fiber printing parameters on composite parts. The results indicate that the 3D-printed glass fibers consist of nylon, continuous glass fibers, and voids (porosity), which range from 58% to 63%, 31% to 38%, and 5% to 8%, respectively. Mechanical characterizations indicate that printing fiber layers in blocks results in superior mechanical properties compared to printing alternating layers of glass fibers and Onyx. Additionally, the concentric mode of fiber printing can be challenging if the ‘start rotation’ parameter is not adjusted correctly. Premature specimen breakage occurred when fiber printing began within their useful length, resulting in a deformation at break that was approximately 34% less, depending on the starting position. The proposed analytical and numerical prediction methods had prediction errors of approximately 7% to 12% and 5% to 7%, respectively. Engineers can use these prediction approaches during the dimensioning phase of 3D printed composite parts.