Three-Dimensional Printed Continuous Fiber-Reinforced Polymer Composites: A Brief Review

Document Type : compile

Authors

1 - Department of Mechanical Engineering, University of Kashan, Kashan, Iran

2 Faculty of Mechanical Engineering; University of ,Kashan; Kashan

Abstract

Fiber reinforced composites offer exceptional directional mechanical properties, and the combination of their advantages with the capability of 3D printing has been resulted in many innovative research fronts. Three-dimensional printing technology is most widely used in automotive, aerospace, building, metal and alloy, electronics and biomedical industries. The most notable reason for the widespread acceptance of this technology is the ability to create intricate design at minimized process steps with the freedom to fabricate reinforcement as required. This review aims to summarize the methods and findings of research conducted on 3D-printed continous fiber reinforced composites by fused deposition modeling (FDM). It is shown that factors affecting the fabrication of these composites such as fiber orientation, fiber volume fraction and stacking sequence as well as, printing parameters such as infill density, infill pattern, nozzle speed, layer thickness, built orientation, nozzle and bed temperatures have a great effect on mechanical properties. In the present paper, a brief history of the three-dimensional printing of continous fiber reinforced composites, mechanism of embedding different continuous fibers into different plastics and their microstructural and mechanical properties including predicting models have been reviewed. In addition, future research is defined based on current constraints and challenges.

Keywords


1. Wang X., Jiang M., Zhou Z., Gou J., and Hui D., 3D Printing of Polymer Matrix Composites: A Review and Prospective,
Compos. Part B: Eng., 110, 442-458, 2017.
2. Liu Z., Wang Y., Wu B., Cui C., Guo Y., and Yan C., A Critical Review of Fused Deposition Modeling 3D Printing
Technology in Manufacturing Polylactic Acid Parts, Int. J. Adv. Manuf. Technol., 102, 2877–2889, 2019.
3. Matsuzaki R., Ueda M., Namiki M., Jeong T., Asahara H., Horiguchi K., Nakamura T. et al., Three-Dimensional Printing
of Continuous-Fiber Composites by In-Nozzle Impregnation, Sci. Rep., 6, 23058, 2016.
4. Oztan C., Karkkainen R., Fittipaldi M., Nygren G., Roberson L., Lane M., and Celik E., Microstructure and Mechanical
Properties of Three Dimensional-Printed Continuous Fiber Composites, J. Compos. Mater, 53, 271-280, 2019.
5. Yang C., Tian X., Liu T., Cao Y., and Li D., 3D Printing for Continuous Fiber-Reinforced Thermoplastic Composites:
Mechanism and Performance, Rapid Prototyp. J., 23, 209- 215, 2017.
6. Kabir S.M.F., Mathur K., and Seyam A.M., A Critical Review on 3D Printed Continuous Fiber-Reinforced Composites:
History, Mechanism, Materials and Properties, Compos. Struct., 19, 32270-6, 2019.
7. Heidari-Rarani M., Rafiee-Afarani M., and Zahedi A.M., Mechanical Characterization of FDM3 D Printing of
Continuous Carbon Fiber Reinforced PLA Composites, Compos. Part. B: Eng., 175, 442-458, 2019.
8. Behzadnasab M. and Yousefi A.A., Effects of 3D Printer Nozzle Head Temperature on the Physical and Mechanical Properties of PLA Based Product, 12th International Seminar on Polymer Science and Technology, Tehran, 2-5 November, 2016.
9. Papon E.A., Haque A., and Spear S.K., Effects of Fiber Surface Treatment and Nozzle Geometry in Structural Properties of Additively Manufactured Two-Phase Composites, AIAA Scitech 2019 Forum, San Diego, California, 7-11 January,
2019.
10. Ning F., Cong W., Hu Y., and Wang H., Additive Manufacturing of Carbon Fiber-Reinforced Plastic Composites Using Fused Deposition Modeling: Effects of Process Parameters on Tensile Properties, J. Compos. Mat., 51, 451-462, 2017.
11. Chacón J.M., Caminero M.A., García-Plaza E., and Núñez P.J., Additive Manufacturing of PLA Structures Using Fused
Deposition Modelling: Effect of Process Parameters on Mechanical Properties and Their Optimal Selection, Mater.
Des., 124, 143-157, 2017.
12. Mei H., Ali Z., Ali I., and Cheng L., Tailoring Strength and Modulus by3 D Printing Different Continuous Fibers and
Filled Structures into Composites, Adv. Compos. Hyb. Mater., 2, 312–319, 2019.
13. Lozada J.N., Ahuett-Garza H., Orta-Castañón P., Verbeeten W., and Sáiz-González D., Tensile Properties and Failure Behavior of Chopped and Continuous Carbon Fiber Composites Produced by Additive Manufacturing, Addit. Manuf., 26, 227- 241, 2019.
14. Caminero M.A., Chacón J.M., García-Moreno I., and Rodríguez G.P., Impact Damage Resistance of 3D Printed
Continuous Fibre Reinforced Thermoplastic Composites Using Fused Deposition Modelling, Compos. Part B: Eng.,
148, 93-103, 2018.
15. Fuenmayor E., Forde M., Healy A.V., Devine D.M., Lyons J.G., McConville C., and Major I., Material Considerations
for Fused-Filament Fabrication of Solid Dosage Forms, Pharmaceutics, 10, 44, 2018.
16. Rahim T.N.A.T., Abdullah A.M., and Akil H. Md., Recent Developments in Fused Deposition Modeling-Based 3D
Printing of Polymers and their Composites, Polym. Rev., 59, 589-624, 2019.
17. Vanzanella V., Scatto M., Zant E., Sisani M., Bastianini M., and Grizzuti N., The Rheology of PEOT/PBT Block
Copolymers in the Melt State and in the Thermally-Induced Sol/Gel Transition Implications on the 3D-Printing Bioscaffold
Process, Materials, 12, 226, 2019.
18. Tiwari K. and Kumar S., Analysis of the Factors Affecting the Dimensional Accuracy of 3D Printed Products, Mater. Today. Proc., 5, 18674-18680, 2018.
19. Chabaud G., Castro M., Denoual A.C., and Duigou L., Hygromechanical Properties of 3D Printed Continuous
Carbon and Glass Fibre-Reinforced Polyamide Composite for Outdoor Structural Applications, Addit. Manuf., 26, 12, 2019.
20. Goh G., Dikshit V., Nagalingam A.P., Goh G.L., AgarwalaS., Sing S.L., Wei J., and Yeong W.Y., Characterization of
Mechanical Properties and Fracture Mode of Additively Manufactured Carbon Fiber and Glass Fiber-Reinforced
Thermoplastics, Mater. Des., 137, 79-89, 2018.
21. Tian X., Liu T., Yang C., Wang Q., and Li D., Interface and Performance of 3D Printed Continuous Carbon Fiber-Reinforced PLA Composites, Compos. Part A: Appl. Sci. Manuf., 88, 198- 205, 2016.
22. Meng L., Xiaoyong T., Junfan S., Weijun Z., Dichen L., and Yingjie Q., Impregnation and Interlayer Bonding Behaviours
of 3D-Printed Continuous Carbon-Fiber-Reinforced Polyether- ether-ketone Composites, Compos. Part A: Appl. Sci.
Manuf., 121, 130-138, 2019.
23. Melenka G.W., Cheung B.K.O., Schofield J.S., Dawson M.R., and Carey J.P., Evaluation and Prediction of the Tensile
Properties of Continuous Fiber-Reinforced 3D Printed Structures, Compos. Struct., 153, 866-875, 2016.
24. Van De Werken N., Hurley J., Khanbolouki P., Sarvestani A.N., Tamijani A.Y., and Tehrani M., Design Considerations
and Modeling of Fiber-Reinforced 3D Printed Parts, Compos. Part B: Eng., 160, 684-692, 2019.
25. Parandoush P., Zhou C., and Lin D., 3D Printing of Ultrahigh Strength Continuous Carbon Fiber Composites, Adv. Eng.
Mater., 21, 1800622, 2019.
26. Justo J., Távara L., García-Guzmán L., and París F., Characterization of 3D Printed Long Fibre Reinforced Composites, Compos. Struct., 185, 537-548, 2018.
27. Ye W., Lin G., Wu W., Geng P., Hu X., Gao Z., and Zhao J., Separated 3D Printing of Continuous Carbon Fiber-Reinforced
Thermoplastic Polyimide, Compos. Part A: Appl. Sci. Manuf., 121, 457-464, 2019.
28. Liu T., Tian X., Zhang M., Abliz D., Li D., and Ziegmann G., Interfacial Performance and Fracture Patterns of 3D
Printed Continuous Carbon Fiber with Sizing Reinforced PA6 Composites, Compos. Part A: Appl. Sci. Manuf., 114, 368-
376, 2018.
29. Al Abadi H., Thai H.T., Paton-Cole V., and Patel V.I., Elastic Properties of 3D Printed Fibre-Reinforced Structures, Compos. Struct., 193, 8-18, 2018.
30. Akhoundi B., Behravesh A.H., and Bagheri-Saed A., Improving Mechanical Properties of Continuous Fiber-
Reinforced Thermoplastic Composites Produced by FDM 3D Printer, J. Reinf. Plast. Compos., 38, 99-116, 2019