Abstract:
A continuous carbon fiber reinforced Polymer was manufactured using a Fused
Deposition Modelling method. Current Fused Deposition Modelling machine are not
able to manufacture Carbon Fiber Reinforced Thermoplastic Polymer composite
therefore modification and novel designs needed to be made and integrated to the
Fused Deposition Modelling machine to achieve a final product. To investigate the
benefits of our composite a comparison with available composites on the market
composed of similar materials needed to be performed. We investigated the different
aspect of the requirements needed to manufacture test samples. We focused on
manufacturing method able to integrate continuous Carbon Fiber simultaneously to a
thermoplastic. In the slicing software a custom g code sequence has been developed
to forward the continuous Carbon Fiber through the Bowden tube to the hotend. This
procedure allowed the hotend to move freely between the layup of the printed part.
Also C code library has been developed to analyse the geometry of the part to
recognise the amount of Carbon Fiber, which needs to be pushed through the Bowden
tube connected to the hotend. We investigated the mechanical properties as well as
the process parameters of the individual materials used to manufacture our Carbon
Fiber Reinforced Thermoplastic Polymer samples. In addition Carbon Fiber
Reinforced Thermoplastic low velocity impact samples have been produced to
investigate the potential of our composite in comparison to available products on the
marker like Short Carbon Fiber Polyamide filaments. The low velocity performances
of the Continuous Carbon Fiber Thermoplastic Polymer samples have been promising
compared to conventional Short Carbon Fiber Polyamide samples. The advantages
of using an Fused Deposition Modelling machine to manufacture composites is the
ease to choose between numerous fiber orientations, which a significantly important
feature for impact applications. In addition a potential case study for aerospace
structure applications of our Carbon Fiber Reinforced Thermoplastic Polymer will be
investigated and discussed. The novelty behind this is research is in the coding
sequence allowing the fiber cutting system to trigger a the a specific moment in order
to integrate the necessary amount of fiber according to the distance of the hotend
travelled on the heat bed. Another novelty is in the unique servo actuated fiber cutting
system using a specific cutting mechanism. The contribution to the knowledge is the
study of the behaviour of a thermoplastic composite under low velocity impact. To
investigate the effect of process parameters on a thermoplastic composite. To develop
a novel cutting system and code control. Vibration cancellation method for even and
continuous integration of continuous carbon fiber cutting method for precise carbon
fiber cutting and integration to thermoplastic via Bowden extrusion system. Coding for
the motherboard firmware as well as G code for the slicer have been optimised in
order to produce quality samples. The effect of hardware on process parameters have
been investigated though tensile tests. Low velocity impact performance of continuous
carbon fiber polyamide has been also investigated and tested.