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Microstructure and Mechanical Performance of 3D-Printed Carbon Fibre-PLA-PHA Composites.

David Bassir1,2, Sofiane Guessasma3

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Summary

Printing angle moderately impacts carbon fibre-PLA/PHA composites made with fused filament fabrication (FFF). Optimal tensile strength was observed at 30°, showing potential for reliable additive manufacturing applications.

Keywords:
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Area of Science:

  • Materials Science and Engineering
  • Additive Manufacturing
  • Composite Materials

Background:

  • Fused filament fabrication (FFF) is a key additive manufacturing technique for polymer composites.
  • Carbon fibre-reinforced polymer composites offer enhanced mechanical properties.
  • Understanding the influence of processing parameters like printing angle is crucial for optimizing composite performance.

Purpose of the Study:

  • To investigate the effect of printing angles (0°, 15°, 30°, 45°) on the thermal and mechanical properties of carbon fibre-PLA/PHA composites.
  • To analyze the microstructural characteristics and porosity of 3D-printed composites.
  • To correlate printing angle with mechanical parameters and deformation mechanisms.

Main Methods:

  • Fabrication of carbon fibre-PLA/PHA composites using FFF.
  • Microstructural analysis via Scanning Electron Microscopy (SEM), X-ray microtomography, and optical imaging.
  • Mechanical testing under tensile loading to determine Young's modulus, tensile strength, and elongation at break.
  • Finite element simulations based on 3D imaging data.

Main Results:

  • Porosity in printed structures ranged from 27% to 38%, significantly higher than the 3% filament porosity.
  • Tensile modulus showed limited sensitivity to printing angle (840-890 MPa), with variations up to 6%.
  • Tensile strength peaked at 37 MPa for a 30° printing angle, with variations up to 16% across tested angles.
  • Finite element simulations confirmed experimental results with an effective solid phase modulus of 1.6-1.8 GPa.

Conclusions:

  • Printing angle has a moderate influence on the mechanical response of carbon fibre-PLA/PHA composites.
  • The composite material exhibits robust structural integrity and interlayer cohesion across various printing angles.
  • These findings highlight the potential of carbon fibre-PLA/PHA composites for reliable structural applications in additive manufacturing.