Modeling and Compensation Methods for Trajectory Errors in Continuous Fiber-Reinforced Thermoplastic Composites Using...

Area of Science:

• Materials Science
• Manufacturing Engineering
• Additive Manufacturing

Background:

• 3D printing of continuous fiber-reinforced thermoplastic composites is hindered by defects like fiber bundle twisting and folding.
• These defects stem from printing trajectory errors, impacting overall component performance.

Purpose of the Study:

• To elucidate the formation mechanism of printing trajectory errors in continuous fiber 3D printing.
• To investigate the influence of geometric parameters (trace curvature, nozzle diameter, fiber bundle diameter) on these errors.
• To develop and validate an error model and compensation method for trajectory errors.

Main Methods:

• Established an error model for printing trajectory based on key geometric parameters.
• Proposed a trajectory error compensation method utilizing maximum printable curvature.
• Utilized a clothoid trajectory for a CCFRF/PA composite case study with specified printing parameters.

Main Results:

• The developed error model accurately predicts printed trajectory errors, especially for obtuse angles.
• Average prediction deviations for line profile, deviation kurtosis, and deviation area ratio were 36.029%, 47.238%, and 2.045%, respectively.
• The compensation method effectively reduced fiber bundle folding and twisting defects.

Conclusions:

• The proposed trajectory error model and compensation method significantly improve the internal quality of 3D printed continuous fiber composites.
• This approach offers a viable solution for mitigating defects and enhancing the performance of additively manufactured fiber composites.
• The method shows potential for broader application in other continuous fiber 3D printing processes.