Recent advances in 3D printed fiber reinforced composites: Processing technique and mechanical performance
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摘要: 3D打印可实现纤维增强复合材料复杂结构的一体化成型,无需模具,可显著降低先进复合材料的制造时间和成本。本文综述了3D打印纤维增强复合材料工艺和力学性能的最新研究进展,对纤维增强复合材料3D打印工艺、打印设备、打印材料和力学性能等方面开展了详细的分析和阐述,重点介绍了熔融沉积工艺成型连续纤维增强复合材料的最新研究进展,并与传统工艺制备的复合材料力学性能进行了对比和分析。最后,针对纤维增强复合材料3D打印技术的未来发展进行了展望。Abstract: 3D printing is an innovative additive manufacturing technology, enabling the integrated moulding of composite structure with a complex contour. 3D printing eliminates the need for the expensive moulds, which can greatly reduce the manufacturing costs and time. This paper reviewed the recent research progress of processing techniques and mechanical performance of 3D printed fiber reinforced composite. Processing techniques, printing equipment, printing materials and mechanical properties of the printed composites were analyzed and discussed in details. More focuses were paid on the recent advances in the continuous fiber reinforced composite prepared by a fused filament fabrication method. Mechanical performance of the composites manufactured by 3D printing and traditional manufacturing techniques were compared. Finally, the existing issues in the research of 3D printed fiber reinforced composites were summarized with the outline of a roadmap for the future research trend in this field.
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图 2 打印设备及制品图片:(a) 斐帛科技桌面级打印机COMBOT-I[37];(b) Markforged公司的桌面级打印机MarkTwo[9];((c)、(d)) Arevo公司的多自由度打印系统AQUA及其打印的自行车架 [12];(e) 按比例缩小的悬挂板的拓扑分析过程;(f) 悬挂板的打印路径和3D打印的悬浮板[39]
Figure 2. Photos of printing equipments and products: (a) Fibertech desktop printer COMBOT-I [37]; (b) Markforged's desktop printer MarkTwo [9]; ((c),(d)) Multi-degree-of-freedom printing system AQUA from Arevo and its 3D printed bike frame[12]; (e) Topological analyzing process of the scaled-down suspension plate; (f) Printing path of the suspension plate and 3D printed suspension plate[39]
图 4 (a) 不同层厚、纤维含量的层间剪切强度(ILSS)样品;(b) 不同层厚、纤维含量和构建方向的缺口冲击样品[78,79]
Figure 4. (a) Interlaminar shear strength (ILSS) samples with different layer thicknesses and fibre volume contents; (b) Notched impact samples with different build orientations, layer thicknesses and fibre volume contents[78,79]
Lt—Layer thicknesses
图 5 不同方向的连续碳纤维/尼龙复合材料的SEM图像:(a) 俯视图;(b) 截面图;(c) 打印的碳纤维丝束在转弯处的纤维断裂;((d)~(f)) 打印复合材料中存在的孔隙[63]
Figure 5. SEM images of different views of carbon fiber/Nylon composites: (a) Top view; (b) Cross-sectional view; (c) Single carbon fiber printed layer with fiber breakage at the curvature; ((d)-(f)) Magnified cross-section showing porosity[63]
表 1 3D打印纤维增强复合材料的制备工艺、材料类型和优缺点[15]
Table 1. Summary of 3D printed fibre-reinforced composites for processing techniques, material types, advantages and disadvantages[15]
Processing techniques Material types Advantages Disadvantages Material extrusion
(FFF, LDM)FFF
Continuous filaments of
thermoplastic polymers
LDM
A concentrated dispersion
of particles in liquidLow cost,
Easy fabrication,
Multi-material capabilityObvious layer-
by-layer effect,
Nozzle clogging at high
fibre volumeVat photopoly-
merization
(SLA)A resin with
photoactive
monomersFine resolution,
Random alignment of discontinuous fibres for isotropic mechanical propertyVery limited materials,
Fibre sedimentation in resin,
UV penetration issue,
Bubble formation causing
pores to formPowder bed fusion
(SLS)Compacted fine
powdersFine resolution,
Unused powder
can be reused,
High loading of reinforcementSlow printing,
Expensive,
High porosity in the
binder method,
Long and continuous fibre reinforcement not possible,
Rough surfaceLaminated object
manufacturing
(LOM, CBAM)Polymer composite
in sheetHigh-strength parts can be produced,
Low cost,
No post processing,
No need for support structuresHigh material wastage,
Difficult to build complex
internal cavitiesNotes: FFF—Fused wire manufacturing; LDM—Liquid deposition molding; SLA—Solid light curing; SLS—Selective laser sintering; LOM—Laminated solid manufacturing technology; CBAM—Composite material based additive manufacturing technology. 表 2 一些用于3D打印材料的物理性能
Table 2. Physical properties of some materials used for 3D printing
Materials Physical and mechanical properties Resource Density/
(g·cm−3)Diameter of printing filament/mm Tensile modulus/
GPaFlexural modulus/
GPaMatrix PA6 1.10 1.75 0.9 2.9 [42] PLA 1.24 1.75 2.0 0.8 [42] ABS 1.04 1.75 1.0 2.40 [42] PEEK 1.30 1.75 3.7 3.6 [43] E-54 − − − − [22] EP-671 − − − − [23] Continuous fiber Carbon fiber 1.30 0.40 54.0 51.0 [42] Glass fiber 2.40 0.30 21.0 22.0 [42] Kevlar fiber 1.20 0.30 27.0 26.0 [42] Jute fiber 1.46 0.80 5.0 − [42] Flax fiber 1.35-1.50 0.30 23.0 − [40, 44] Notes: PA6—Nylon 6; PLA—Poly lactic acid; ABS—Styrene-acrylonitrile-polybutadiene copolymer; PEEK—Polyether-ether-ketone; EP—Epoxy. 表 3 ILSS样品的打印参数和层间剪切强度[79]
Table 3. Printing parameters and interlaminar shear strength of ILSS samples[79]
Sample Fiber volume fraction
(vol%, number of fiber layers/number of layers)ILSS/MPa Carbon
fiberType A 26.8(18/48) 22.2 Type B 72.4(46/48) 31.9 Kevlar
fiberType A 27.5(22/60) 13.7 Type B 73.8(58/60) 14.3 Glass
fiberType A 27.2(22/60) 13.9 Type B 73.4(58/60) 21.0 表 4 缺口冲击样品的打印参数和冲击强度[78]
Table 4. Printing parameters and impact strength of notched impact samples[78]
Sample
Build orientationFiber volume
fraction/vol%Impact strength/
(kJ·m−2)Flat On-edge Flat On-edge Carbon
fiberType A 3.4 3.4 22.2 24.7 Type B 24.9 24.8 33.2 59.8 Type C 53.2 33.2 57.5 82.3 Kevlar
fiberType A 8.6 7.8 30.1 36.4 Type B 29.5 29.5 83.7 95.1 Type C 56.1 34.7 125.5 184.8 Glass
fiberType A 8.4 7.8 74.2 86.3 Type B 29.2 29.7 206.7 246.2 Type C 55.6 34.3 271.2 281.0 表 5 注塑、模压与3D打印工艺成型的碳纤维增强复合材料的力学性能对比
Table 5. Comparison of mechanical properties of carbon fibre reinforced compositesby injection molding, compression molding and 3D printing
Sample Fiber volume fraction/vol% Tensile modulus/
GPaTensile strength/
MPaFlexural modulus/
GPaFlexural strength/
MPaMode I
GIC−i/
(J·m−2)Mode I
GIC−p/
(J·m−2)Ref. CCF/ABS-3DP 10 − 127 − 147 − − [85] CCF/ABS-IM − 140 − 200 − − CCF/PA6-3DP 35 61.0 767 35.8 546 118.5 1467 [83] CCF/PA6-3DP-CM 83.2 940 57.3 1052 225.1 472 3DP 35 − − 52.1 583 − − [87] 3DP-CM − − 69.2 950 − − Notes: CCF—Continuous carbon fiber; ABS—Acrylonitrile butadiene styrene; PA6—Polyamide 6; 3DP—3D powder bonding; GIC−i—Interlaminar fracture toughness values for delamination initiation; GIC−p—Interlaminar fracture toughness after molding; IM—Injection molding; CM—Compression moulding. -
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