Combining Over-3D Printing of Continuous Carbon Fiber Reinforced Composites with Stamp Forming Organo-sheet Substrates https://ift.tt/2M1e1gI Because continuous carbon fiber reinforced polymer composite materials have such high strength, stiffness, and fatigue resistance, in addition to noise suppression and impact energy absorption qualities, a lot of people are naturally interested in them for multiple applications. But, researchers need to look into ways to address related challenges, such as cost-effective processes to manufacture these materials. U. Morales, A. Esnaola, M. Iragi, L. Aretxabaleta, and J. Aurrekoetxea with Mondragon Unibertsitatea published a paper, titled “Over-3D printing of continuous carbon fibre composites on organo-sheet substrates,” that looks at combining FFF 3D printing of continuous fiber reinforced composites with organo-sheet thermoplastic composites.
While stamp forming organo-sheet thermoplastic composites is a cost-effective method, it can’t produce complex geometries on its own, meaning that it requires assembling operations and parts to do so. You can combine stamp forming with over-injection molding, but then the final part’s mechanical properties will be limited. FFF 3D printing can achieve complex geometries and support advanced materials, but it isn’t perfect. So combining over-3D printing on the organo-sheet can offer the best of both worlds. The team’s manufacturing process is three-fold:
A standard polyamide 6 (PA6) was used for the infill material, while the printed composite material was a continuous carbon fiber reinforced polyamide 6 (CF-PA6); both came from Markforged. The company’s desktop Mark Two 3D printer was used to fabricate the over-3D printed specimen, the geometry of which consisted of a 2 x 30 x 90 mm3 organo-sheet substrate and a 4 x 15 x 45 mm3 prismatic over-3D printed part.
The team carried out quasi-static shear tests, studied failure modes by using an optical microscopy to analyze the over-printed fracture zones, and conducted differential scanning calorimetry (DSC) on the samples, which weighed between 5.5 and 6 mg. After all of the experiments had been completed, the researchers felt that their work fully demonstrated a feasible new process that combined stamp forming of carbon fiber reinforced PA12 organo-sheet and over-3D printing of continuous carbon fiber reinforced PA6.
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