Adapted Design Process for Continuous Fiber-Reinforced Additive Manufacturing-A Methodological Framework

Area of Science:

• Additive Manufacturing
• Materials Science
• Mechanical Engineering

Background:

• Continuous fiber-reinforced material extrusion (CFMRE) is an emerging additive manufacturing (AM) technology.
• It combines AM benefits with composite material properties for high-strength, lightweight parts.
• Current design methods inadequately address CFMRE's unique aspects like anisotropy and functional integration.

Purpose of the Study:

• To propose a tailored methodology for designing components using CFMRE.
• To bridge the gap between existing design for AM methods and CFMRE's specific requirements.
• To enhance the design process for continuous fiber-reinforced material extrusion.

Main Methods:

• Developed a tailored methodology building on established process models for CFMRE.
• Integrated process-specific methods, including a process selection analysis.
• Created a decision model for selecting CFMRE for highly stressed components.
• Presented a detailed design process specifically for CFMRE.

Main Results:

• A novel methodology for designing continuous fiber-reinforced material extrusion components was developed.
• Process-specific methods and a decision model were integrated into the methodology.
• The methodology addresses CFMRE's unique design considerations, such as anisotropy.
• A case study demonstrated the application of the developed process model.

Conclusions:

• The proposed methodology provides a tailored approach for designing with CFMRE.
• It enhances the capability to leverage CFMRE for high-strength component manufacturing.
• Further development in design for CFMRE is crucial for this emerging technology.