Additive Manufacturing of Continuous Fiber-Reinforced Polymer Composites via Fused Deposition Modelling: A...

Area of Science:

• Materials Science
• Manufacturing Engineering
• Polymer Science

Background:

• Additive manufacturing (AM) offers advanced capabilities for creating complex geometries with improved mechanical properties.
• Continuous Fiber-Reinforced Polymer Composites (CFRPCs) are increasingly important for high-performance applications.
• Fused Deposition Modeling (FDM) is a versatile and cost-effective AM technique for CFRPC fabrication.

Purpose of the Study:

• To critically review the influence of process-printing parameters on the additive manufacturing of CFRPCs using FDM.
• To identify optimal processing parameters by analyzing existing research on mechanical properties.
• To highlight advancements, challenges, and future opportunities in CFRPC AM via FDM.

Main Methods:

• Systematic review of existing research literature on FDM of CFRPCs.
• Analysis of process parameters including fiber orientation, layer thickness, nozzle diameter, fiber volume fraction, printing temperature, and infill design.
• Visual representation of process parameters and their impact on mechanical, physical, and thermal properties.

Main Results:

• Continuous fiber filaments offer superior strength compared to short fibers, but delamination remains a challenge.
• Various printing parameters significantly influence the AM process and resulting mechanical properties.
• Optimal processing parameters can be inferred from existing studies to enhance CFRPC fabrication.

Conclusions:

• Establishing the relationship between printing parameters and mechanical properties is crucial for optimizing CFRPC manufacturing via FDM.
• Further research is needed to address limitations such as delamination and optimize parameter control.
• Optimized CFRPC fabrication through FDM enables the development of lightweight, high-strength components for diverse industrial applications.