development of improved fibre reinforced feedstocks … · fibre reinforced feedstocks ... 3d...
TRANSCRIPT
Lourens Blok, Marco Longana, HaNa
Yu, Ben Woods
Development of improved
fibre reinforced feedstocks
for high performance 3D
printing
Overview
INTRODUCTION
• Current composite 3D printing
• Improved composite 3D printing
FILAMENT DEVELOPMENT
• HiPerDiF fibre alignment
• Short fibre thermoplastic preforms
• Filament forming
FUTURE WORK
• Fibre alignment in thermoplastic melt flow
Current composite 3D printing
Additive manufacturing (AM) approach for composite laminates
• Build up part layer-by-layer, no need for autoclave or large press, instead use desktop printer
• Fibres pre-embedded in thermoplastic filament
Printing of microfibres
[Ning et al.] [Tekinalp et al.]
Stiffness: 14 GPaStrength: 65 MPaFibre volume content ~20%
Printing of continuous fibres
Stiffness: 50 GPaStrength: 700 MPaFibre volume content ~25%
<->
[Blok et al.]
Improved composite 3D printing
Thermoplastic filament with discontinuous fibres above the critical fibre length
• Allows for full strength of fibre to be reached
Sweet spot
HiPerDiF FilamentDevelop 3D printing feedstock with discontinuous fibres above the critical fibre length
HiPerDiF fibrealignment
Consolidation withthermoplastic matrix
Uniform filamentforming
3D printing of short fibre composites
HiPerDiF Filament
[1]
Develop 3D printing feedstock with discontinuous fibres above the critical fibre length
[Yu et al., 2014]
HiPerDiF/epoxy Strength: 1509MPa Stiffness: 115GPa
(Vf = 55%)
HiPerDiF fibrealignment
Consolidation withthermoplastic matrix
Uniform filamentforming
3D printing of short fibre composites
HiPerDiF Filament
HiPerDiF fibrealignment
Consolidation withthermoplastic matrix
Uniform filamentforming
3D printing of short fibre composites
Develop 3D printing feedstock with discontinuous fibres above the critical fibre length
Mechanical properties of short fibre thermoplastic composites with a fibre volume fraction of 12%
Fabrication of short fibre thermoplastic preforms with a cross section of 5mm x 0.2 mm
HiPerDiF Filament
METHOD: Custom nozzle contraction with glass plate to track fibre alignment
HiPerDiF fibrealignment
Consolidation withthermoplastic matrix
Uniform filamentforming
3D printing of short fibre composites
GOAL: Forming of short fibre thermoplastic preforms tapes into circular filament
5mm x 0.2mm
φ 1.2 mm
Develop 3D printing feedstock with discontinuous fibres above the critical fibre length
HiPerDiF Filament
HiPerDiF fibrealignment
Consolidation withthermoplastic matrix
Uniform filamentforming
3D printing of short fibre composites
Medical applications Rapid prototyping Home applications
Develop 3D printing feedstock with discontinuous fibres above the critical fibre length
Aerospace applications
Future work
• Study rheological behavior of fibres in thermoplastic melt
• Simulate fibres flowing in polymer melt using particle based method
• Model fibres as rigid bodies or as boundary constraints (linked particles)
Fibres represented
by linked particles
Matrix represented by
free flowing particles
Lourens Blok, Marco Longana, HaNa
Yu, Ben Woods
Development of improved
fibre reinforced feedstocks
for high performance 3D
printing
Questions?