Skip to main content
SpringerLink
Log in

Manufacturing and 3D printing of continuous carbon fiber prepreg filament

  • Composites
  • Published:
Journal of Materials Science Aims and scope Submit manuscript

Abstract

The current research proposes a novel method for printing continuous carbon fiber composite parts. At first, continuous carbon fiber prepreg filament for Fused Deposition Modeling 3D printing was manufactured, followed by modification of extruder head of 3D printers to print the filament. Thereafter, three-point flexural test and Response Surface Methodology were adopted to study the mechanical properties of the composite parts printed with the filament. After testing, a mathematical model was developed to describe and analyze the relationship between the printing parameters (printing temperature, printing speed, and layer thickness) and the flexural strength of printed composite parts. We discovered that the flexural strength and flexural modulus of printed composites significantly improved with the proposed method with specified printing parameters, and while of all the parameters, the layer thickness had the greatest contribution towards the final flexural strength. The results indicate that the discussed method could be a promising approach to print CCF composites.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10

Similar content being viewed by others

References

  1. Snyder TJ, Andrews M, Weislogel M, Moeck P, Stone-Sundberg J, Birkes D, Friedman S (2014) 3D systems’ technology overview and new applications in manufacturing engineering science and education. 3D Print Addit Manuf 1(3):169–176

    Article  Google Scholar 

  2. Horn TJ, Harrysson OL (2012) Overview of current additive manufacturing technologies and selected applications. Sci Prog 95(3):255–282

    Article  Google Scholar 

  3. Turner NB, Strong R, Gold SA (2014) A review of melt extrusion additive manufacturing processes: I. Process design and modeling. Rapid Prototyp J 20(3):192–204

    Article  Google Scholar 

  4. Bellini A, Güçeri S (2003) Mechanical characterization of parts fabricated using fused deposition modeling. Rapid Prototyp J 9(4):252–264

    Article  Google Scholar 

  5. Wang J, Xie H, Weng Z, Senthil T, Wu L (2016) A novel approach to improve mechanical properties of parts fabricated by fused deposition modeling. Mater Des 105:152–159

    Article  Google Scholar 

  6. Dul S, Fambri L, Pegoretti A (2016) Fused deposition modelling with ABS–graphene nanocomposites. Compos A Appl Sci Manuf 85:181–191

    Article  Google Scholar 

  7. Prashantha K, Roger F (2017) Multifunctional properties of 3D printed poly (lactic acid)/graphene nanocomposites by fused deposition modeling. J Macromol Sci A 54(1):24–29

    Article  Google Scholar 

  8. Bettini P, Alitta G, Sala G, Di Landro L (2017) Fused deposition technique for continuous fiber reinforced thermoplastic. J Mater Eng Perform 26(2):843–848

    Article  Google Scholar 

  9. Ashori A, Menbari S, Bahrami R (2016) Mechanical and thermo-mechanical properties of short carbon fiber reinforced polypropylene composites using exfoliated graphene nanoplatelets coating. J Ind Eng Chem 38:37–42

    Article  Google Scholar 

  10. Hull E, Grove W, Zhang M, Song X, Pei ZJ, Cong W (2015) Effects of process variables on extrusion of carbon fiber reinforced ABS filament for additive manufacturing. In: ASME 2015 international manufacturing science and engineering conference, American Society of Mechanical Engineers. pp V001T02A065–V001T02A065

  11. Ning F, Cong W, Qiu J, Wei J, Wang S (2015) Additive manufacturing of carbon fiber reinforced thermoplastic composites using fused deposition modeling. Compos B Eng 80:369–378

    Article  Google Scholar 

  12. Tekinalp HL, Kunc V, Velez-Garcia GM, Duty CE, Love LJ, Naskar AK, Ozcan S (2014) Highly oriented carbon fiber–polymer composites via additive manufacturing. Compos Sci Technol 105:144–150

    Article  Google Scholar 

  13. Quan Z, Larimore Z, Wu A, Yu J, Qin X, Mirotznik M, Chou TW (2016) Microstructural design and additive manufacturing and characterization of 3D orthogonal short carbon fiber/acrylonitrile-butadiene-styrene preform and composite. Compos Sci Technol 126:139–148

    Article  Google Scholar 

  14. Li ZH, Rong RY, Li YX, Li J (2011) Effect of fiber length on mechanical properties of short carbon fiber reinforced PTFE composites. In: Advanced materials research, Trans Tech Publications, vol 311. pp 193–196

  15. Ráthy I, Kuki Á, Borda J, Deák G, Zsuga M, Marossy K, Kéki S (2012) Preparation and characterization of poly (vinyl chloride)–continuous carbon fiber composites. J Appl Polym Sci 124(1):190–194

    Article  Google Scholar 

  16. Fischer A, Rommel S, Bauernhansl T (2013) New fiber matrix process with 3D fiber printer—a strategic in-process integration of endless fibers using fused deposition modeling (FDM). In: NEW PROLAMAT. pp 167–175

  17. Prüß H, Vietor T (2015) Design for fiber-reinforced additive manufacturing. J Mech Des 137(11):111409-1–111409-7

    Article  Google Scholar 

  18. Li N, Li Y, Liu S (2016) Rapid prototyping of continuous carbon fiber reinforced polylactic acid composites by 3D printing. J Mater Process Technol 238:218–225

    Article  Google Scholar 

  19. Matsuzaki R, Ueda M, Namiki M, Jeong TK, Asahara H, Horiguchi K, Hirano Y (2016) Three-dimensional printing of continuous-fiber composites by in-nozzle impregnation. Sci Rep 6:23058-1–23058-7

    Article  Google Scholar 

  20. Tian X, Liu T, Yang C, Wang Q, Li D (2016) Interface and performance of 3D printed continuous carbon fiber reinforced PLA composites. Compos A Appl Sci Manuf 88:198–205

    Article  Google Scholar 

  21. Mori KI, Maeno T, Nakagawa Y (2014) Dieless forming of carbon fibre reinforced plastic parts using 3D printer. Proced Eng 81:1595–1600

    Article  Google Scholar 

  22. Bezerra MA, Santelli RE, Oliveira EP, Villar LS, Escaleira LA (2008) Response surface methodology (RSM) as a tool for optimization in analytical chemistry. Talanta 76(5):965–977

    Article  Google Scholar 

  23. Aslan N, Cebeci Y (2007) Application of Box–Behnken design and response surface methodology for modeling of some Turkish coals. Fuel 86(1):90–97

    Article  Google Scholar 

  24. Rankouhi B, Javadpour S, Delfanian F, Letcher T (2016) Failure analysis and mechanical characterization of 3D printed ABS with respect to layer thickness and orientation. J Fail Anal Prev 16(3):467–481

    Article  Google Scholar 

  25. NatureWorks Inc. (2013) Biopolymer 4043D technical data sheet. http://www.natureworksllc.com/~/media/Files/NatureWorks/Technical-Documents/Technical-Data-heets/TechnicalDataSheet_4043D_films_pdf.pdf

  26. Aized T, Shirinzadeh B (2011) Robotic fiber placement process analysis and optimization using response surface method. Int J Adv Manuf Technol 55(1):393–404

    Article  Google Scholar 

  27. Gang ZF, Hong DX, Lin WY et al (2016) Mechanical performance of carbon fiber-reinforced polylactide matrix (C/PLA) composites(I). J Mater Eng 5:16–18

    Google Scholar 

  28. Markforged Inc. (2016) Mechanical properties of continuous fibers. https://markforged.com/ty/download-data-sheet/

  29. Afrose MF (2016) Mechanical and viscoelastic properties of polylactic acid (PLA) materials processed through fused deposition modelling (FDM). Doctoral dissertation, Swinburne University of Technology

  30. Shubham P, Sikidar A, Chand T (2016) The influence of layer thickness on mechanical properties of the 3D printed ABS polymer by fused deposition modeling. In: Key engineering materials, Trans Tech Publications, vol 706. pp 63–67

Download references

Acknowledgements

This work was supported by the http://dx.doi.org/10.13039/501100001809 National Nature Science Foundation of China (NSFC) under Grant No. 51405305 and the Shanghai Key Laboratory of Intelligent Manufacturing and Robotics under Grant No. ZK1304. The authors would like to thank the colleges of Aerospace System Engineering Shanghai for their assistance.

Author information

Authors and Affiliations

  1. Rapid Manufacturing Engineering Center, School of Mechatronical Engineering and Automation, Shanghai University, Shanghai, 200444, China

    Qingxi Hu, Yongchao Duan & Haiguang Zhang

  2. Shanghai Key Laboratory of Spacecraft Mechanism, Aerospace System Engineering Shanghai, Shanghai, 201108, China

    Yongchao Duan, Dali Liu, Biao Yan & Fujun Peng

  3. National Demonstration Center for Experimental Engineering Training Education, Shanghai University, Shanghai, 200444, China

    Qingxi Hu & Haiguang Zhang

  4. Shanghai Key Laboratory of Intelligent Manufacturing and Robotics, Shanghai University, Shanghai, 200444, China

    Qingxi Hu & Haiguang Zhang

Authors
  1. Qingxi Hu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yongchao Duan
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Haiguang Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Dali Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Biao Yan
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Fujun Peng
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding authors

Correspondence to Haiguang Zhang or Dali Liu.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Hu, Q., Duan, Y., Zhang, H. et al. Manufacturing and 3D printing of continuous carbon fiber prepreg filament. J Mater Sci 53, 1887–1898 (2018). https://doi.org/10.1007/s10853-017-1624-2

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s10853-017-1624-2

Keywords

Search

Navigation