Bionic Design and 3D Printing of Continuous Carbon Fiber-Reinforced Polylactic Acid Composite with Barbicel Structure of Eagle-Owl Feather

Inspired by eagle-owl feather with characteristics of light weight and high strength, the bionic continuous carbon fiber-reinforced polylactic acid composite with barbicel structure was successfully 3D printed. Under the action of external load, angles between barbicels and rachis structure of eagle-owl feather decreased, which consumed a part of energy and built structure base of bionic feather structure model with a certain arrangement angle of continuous carbon fiber. Variation of bionic structure model design parameters significantly affected the mechanical properties of the 3D printing bionic composites. The relatively low continuous carbon fiber content on tensile force direction restricted enhancement of tensile strength of bionic composite. However, attributed to different angle arrangement of continuous carbon fiber, the propagation of cracks in bionic composite was hindered, exhibiting high impact resistance. The effective and feasible bionic feather design and 3D printing of continuous carbon fiber-reinforced polylactic acid composite extended the corresponding application in the areas with high impact loads.     

Creep Age Forming of Fiber Metal Laminates: Effects of Process Time and Temperature and Stacking Sequence of Core Material

Fiber metal laminates (FMLs) are a type of hybrid materials interlacing composites and metals. In the present work, FMLs with aluminum alloy 6061 as the skin and E-glass fiber-reinforced polypropylene (PP) as the core material are fabricated and formed by the creep age forming (CAF) process. The effects of time and temperature as the process parameters and thickness and stacking sequences of composites layers as the FML parameters are evaluated on the springback of glass-reinforced aluminum laminates (GLARE) FMLs. After the CAF process, the springback of creep age-formed FMLs is calculated. The results show that the FMLs can be successfully formed with the CAF process by considering appropriate time and temperature. In addition, the stacking sequence of composite layers can affect the springback behavior of FMLs significantly.     

3D Printing of Fiber-Reinforced Plastic Composites Using Fused Deposition Modeling: A Status Review

Composite materials are a combination of two or more types of materials used to enhance the mechanical and structural properties of engineering products. When fibers are mixed in the polymeric matrix, the composite material is known as fiber-reinforced polymer (FRP). FRP materials are widely used in structural applications related to defense, automotive, aerospace, and sports-based industries. These materials are used in producing lightweight components with high tensile strength and rigidity. The fiber component in fiber-reinforced polymers provides the desired strength-to-weight ratio; however, the polymer portion costs less, and the process of making the matrix is quite straightforward. There is a high demand in industrial sectors, such as defense and military, aerospace, automotive, biomedical and sports, to manufacture these fiber-reinforced polymers using 3D printing and additive manufacturing technologies. FRP composites are used in diversified applications such as military vehicles, shelters, war fighting safety equipment, fighter aircrafts, naval ships, and submarine structures. Techniques to fabricate composite materials, degrade the weight-to-strength ratio and the tensile strength of the components, and they can play a critical role towards the service life of the components. Fused deposition modeling (FDM) is a technique for 3D printing that allows layered fabrication of parts using thermoplastic composites. Complex shape and geometry with enhanced mechanical properties can be obtained using this technique. This paper highlights the limitations in the development of FRPs and challenges associated with their mechanical properties. The future prospects of carbon fiber (CF) and polymeric matrixes are also mentioned in this study. The study also highlights different areas requiring further investigation in FDM-assisted 3D printing. The available literature on FRP composites is focused only on describing the properties of the product and the potential applications for it. It has been observed that scientific knowledge has gaps when it comes to predicting the performance of FRP composite parts fabricated under 3D printing (FDM) techniques. The mechanical properties of 3D-printed FRPs were studied so that a correlation between the 3D printing method could be established. This review paper will be helpful for researchers, scientists, manufacturers, etc., working in the area of FDM-assisted 3D printing of FRPs.     

Investigation into Thermomechanical Response of Polymer Composite Materials Produced through Additive Manufacturing Technologies

This paper presents the static mechanical behavior and the dynamic thermomechanical properties of four market-available reinforced and non-reinforced thermoplastics and photopolymer materials used as precursors in different additive manufacturing technologies. This article proposes a characterization approach to further address development of aeronautic secondary structures via 3D-printed composite materials replacing conventional manufactured carbon fiber reinforced polymer (CFRP) composites. Different 3D printing materials, technologies, printing directions, and parameters were investigated. Experimental results showed that carbon-reinforced ONYX_R material exhibits a transition point at 114 °C, a 600 MPa tensile strength, and an average tensile strain of 2.5%, comparable with conventional CFRP composites manufactured via autoclave, making it a suitable candidate for replacing CFRP composites, in the aim of taking advantage of 3D printing technologies. ONYX material exhibits higher stiffness than Acrylonitrile-Butadiene-Styrene Copolymer (ABS), or conventional Nylon 6/6 polyamide, the flexural modulus being 2.5 GPa; nevertheless, the 27 °C determined transition temperature limits its stability at higher temperature. Daylight High Tensile (further called HTS) resin exhibits a tensile strength and strain increase when shifting the printing direction from transversal to longitudinal, while no effect was observed in HighTemp DL400 resin (further called HTP).     

Mechanical Performance of 3D Printed Concrete in Steam Curing Conditions

Three-dimensional (3D) concrete printing (3DCP) technology attracts significant attention from research and industry. Moreover, adequate mechanical performance is one of the primary properties for materials, meeting the demand of structural safety using 3DCP technology. However, research on curing conditions as the significant influence factor of mechanical capacity is required to accelerate the practical application of 3DCP technology. This study aims to explore the impact of various steam curing conditions (heating rate, constant temperature time, and constant temperature) on the mechanical performance of printed concrete containing solid wastes. Moreover, the optimal steam curing conditions are obtained for compressive, tensile, and flexural properties in different directions. Subsequently, anisotropies in the mechanical properties of printed composites and interlayer bonding behaviors are investigated when various curing conditions are employed. The result shows that steam curing conditions and solid waste incorporation improves the interlayer bond for 3D printed cement-based composites.     

Experimental Investigation on the Low Velocity Impact Response of Fibre Foam Metal Laminates

The combination of fibre metal laminates (FML) and sandwich structures can significantly increase the performance under impact of FMLs. The goal of this work was to create a material that will combine the superior properties of FMLs and foam sandwich structures in terms of the impact resistance and simultaneously have lower density and fewer disadvantages related to the manufacturing. An extensive impact testing campaign has been done using conventional fibre metal laminates (carbon- and glass-based) and in the proposed fibre foam metal laminates to assess and compare their behaviour. The main difference was observed in the energy absorption mechanisms. The dominant failure mechanism for fibre foam laminates is the formation of delaminations and matrix cracks while in the conventional fibre metal laminate the main failure mode is fibre cracking due to high local stress concentrations. The reduction in the fibre cracking leads to a better after-impact resistance of this type of structure improving the safety of the structures manufactured with these materials.     

Polymer–Nickel Composite Filaments for 3D Printing of Open Porous Materials

Catalysis has been a key way of improving the efficiency-to-cost ratio of chemical and electrochemical processes. There have been recent developments in catalyst materials that enable the development of novel and more sophisticated devices that, for example, can be used in applications, such as membranes, batteries or fuel cells. Since catalytic reactions occur on the surface, most catalyst materials are based on open porous structures, which facilitates the transport of fluids (gas or liquid) and chemical (or electrochemical) specific surface activity, thus determining the overall efficiency of the device. Noble metals are typically used for low temperature catalysis, whereas lower cost materials, such as nickel, are used for catalysis at elevated temperatures. 3D printing has the potential to produce a more sophisticated fit for purpose catalyst material. This article presents the development, fabrication and performance comparison of three thermoplastic composites where PLA (polylactic acid), PVB (polyvinyl butyral) or ABS (acrylonitrile butadiene styrene) were used as the matrix, and nickel particles were used as filler with various volume fractions, from 5 to 25 vol%. The polymer–metal composites were extruded in the form of filaments and then used for 3D FDM (Fused Deposition Modeling) printing. The 3D printed composites were heat treated to remove the polymer and sinter the nickel particles. 3D printed composites were also prepared using nickel foam as a substrate to increase the final porosity and mechanical strength of the material. The result of the study demonstrates the ability of the optimized filament materials to be used in the fabrication of high open porosity (over 60%) structures that could be used in high-temperature catalysis and/or electrocatalysis.     

The Synergistic Effect of Temperature and Loading Rate on Deformation for Thermoplastic Fiber Metal Laminates

The glass fiber reinforced polypropylene/AA2024 hybrid laminates (short for Al/Gf/PP laminates) as structural materials were prepared and formed by hot pressing. The synergistic effects of temperature and loading speed on the laminate deformation under tensile and bending conditions were investigated and analyzed in this study. In tension, stress–strain curves presented bimodal types effected by tensile rates and temperatures. The state of PP resin determines the mechanical behavior of the FMLs. The tensile rate has no effect on FML deformation without heating or over the melting point of PP resin (about 170 °C). The softening point of PP resin (about 100 °C) is characteristic temperature. When the temperature exceeds the softening point but does not reach the melting point, the tensile strength and elongation will demonstrate coordinated growth at a relatively high tensile speed. The efficiency of fiber bridging is affected significantly since the resin is the medium that transfers load from the metal to the fiber. Under bending, the curves presented a waterfall decrement with temperature increment. The softening point of resin matrix is the key in a bending process. When the temperature is near the softening point, deformation is sensitive to both the temperature and the loading speed to a certain extent. If temperature is lower than softening point, deformation is mainly guided by temperature. If the temperature is beyond the softening point, loading speed is in a leading position of deformation. The bending strength gradually increases with loading rate. By using these deformation characteristics, the deformation of the thermoplastic laminates can be controlled in stamping or other plastic forming processes for thermoplastic fiber metal laminates.     

3D Concrete Printing: A Systematic Review of Rheology,Mix Designs,Mechanical, Microstructural,and Durability Characteristics

This paper provides a state-of-the-art report on the up-to-date research on the emerging 3D concrete printing technology from the concrete materials perspective. It reviews the recent research focused on understanding and characterizing the rheological necessities of the concrete printing process and discusses how the researchers are tailoring compatible mix proportions for the 3D concrete printing process by using eco-friendly binders, waste aggregates, chemical admixtures, and nano-additives. This paper systematically evaluates anisotropic behavior in the mechanical properties of printed concrete and establishes an order for anisotropic behavior in the compressive, flexural, and tensile strengths along three different axes (X, Y, and Z axes) of printed concrete. It evaluates the ratio of flexural strength to the compressive strength of printed concrete along the above three axes. This article explains the influence of variation of printing process parameters on the mechanical properties and discusses reinforcement approaches used for increasing structural performance. The microstructure at the interface of adjacent layers and also at the interface of the reinforcement-cement matrix is discussed. The recent research on the durability performance of printed concrete is critically discussed and future research needs for 3D concrete printing are identified in this paper.     

Effect of Fiber Content and Alignment on the Mechanical Properties of 3D Printing Cementitious Composites

This paper studies aligned glass fiber-reinforced composites for printing. To determine the influence of fiber content and alignment on the mechanical properties of this novel material, a large number of standard test specimens were prepared, which included samples fabricated by mold-casting, randomly dispersed fiber reinforced mixtures and aligned fiber cement composites containing 10 types of fiber volume ratios manufactured by nozzle sizes ranging of 24 and 10 mm (fiber length = 12 mm). Mechanical properties and failure modes of the specimens under compression and flexural tests were studied experimentally. The anisotropic behaviors of printed samples were analyzed by different loading directions. As a result, the compressive and flexural strength of printed samples showed obvious anisotropy. With the increase of fiber volume ratio, flexural strength of the fiber reinforced composite was elevated tremendously but its compression strength reduced slightly. Moreover, fiber alignment also had a significant influence on the mechanical properties of the fiber reinforced composite. The composite cement-based material with 1 vol.-% aligned fiber exhibited an excellent flexural strength of 9.38 MPa, which increased by 483% in comparison to that of the plain cement paste.     

Elastic Modulus and Flatwise (Through-Thickness) Tensile Strength of Continuous Carbon Fibre Reinforced 3D Printed Polymer Composites

Additively manufactured composite specimens exhibit anisotropic properties, meaning that the elastic response changes with respect to orientation. Both in-plane and out-of-plane mechanical properties are important for designing purpose. Recent studies have characterised the in-plane performance. In this study, however, through-thickness tensile strength of 3D polymer composites were determined by printing of continuous carbon fibre reinforced thermoplastic polyamide-based composite, manufactured using a Markforged Two 3D printer. This paper discusses sample fabrication and geometry, adhesive used, and testing procedure. Test standards used to determine out-of-plane properties are tedious as most of the premature failures occur between the specimens and the tabs. Two types of samples were printed according to ASTM flatwise tension standard and the results were compared to determine the geometry effect on the interlaminar strength. This test method consists of subjecting the printed sample to a uniaxial tensile force normal to the plane. With this method, the acceptable failure modes for tensile strength must be internal to the structure, not between the sample and the end tabs. Micro-computed tomography (µCT) was carried out to observe the porosity. Surface behaviour was studied using scanning electron microscopy (SEM) to see the voids and the distribution of the fibres in the samples. The results showed consistent values for tensile strength and elastic modulus for Araldite glue after initial trials (with some other adhesives) to determine a suitable choice of adhesive for bonding the samples with the tabs. Circular specimens have higher tensile strength and elastic modulus as compared to rectangular specimens.     

An Overview on the Rheology,Mechanical Properties,Durability, 3D Printing,and Microstructural Performance of Nanomaterials in Cementitious Composites

The most active research area is nanotechnology in cementitious composites, which has a wide range of applications and has achieved popularity over the last three decades. Nanoparticles (NPs) have emerged as possible materials to be used in the field of civil engineering. Previous research has concentrated on evaluating the effect of different NPs in cementitious materials to alter material characteristics. In order to provide a broad understanding of how nanomaterials (NMs) can be used, this paper critically evaluates previous research on the influence of rheology, mechanical properties, durability, 3D printing, and microstructural performance on cementitious materials. The flow properties of fresh cementitious composites can be measured using rheology and slump. Mechanical properties such as compressive, flexural, and split tensile strength reveal hardened properties. The necessary tests for determining a NM’s durability in concrete are shrinkage, pore structure and porosity, and permeability. The advent of modern 3D printing technologies is suitable for structural printing, such as contour crafting and binder jetting. Three-dimensional (3D) printing has opened up new avenues for the building and construction industry to become more digital. Regardless of the material science, a range of problems must be tackled, including developing smart cementitious composites suitable for 3D structural printing. According to the scanning electron microscopy results, the addition of NMs to cementitious materials results in a denser and improved microstructure with more hydration products. This paper provides valuable information and details about the rheology, mechanical properties, durability, 3D printing, and microstructural performance of cementitious materials with NMs and encourages further research.     

Cyclic Relaxation,Impact Properties and Fracture Toughness of Carbon and Glass Fiber Reinforced Composite Laminates

In this paper, the mechanical properties of fiber-reinforced epoxy laminates are experimentally tested. The relaxation behavior of carbon and glass fiber composite laminates is investigated at room temperature. In addition, the impact strength under drop-weight loading is measured. The hand lay-up technique is used to fabricate composite laminates with woven 8-ply carbon and glass fiber reinforced epoxy. Tensile tests, cyclic relaxation tests and drop weight impacts are carried out on the carbon and glass fiber-reinforced epoxy laminates. The surface release energy G_IC and the related fracture toughness K_IC are important characteristic properties and are therefore measured experimentally using a standard test on centre-cracked specimens. The results show that carbon fiber-reinforced epoxy laminates with high tensile strength give high cyclic relaxation performance, better than the specimens with glass fiber composite laminates. This is due to the higher strength and stiffness of carbon fiber-reinforced epoxy with 600 MPa compared to glass fiber-reinforced epoxy with 200 MPa. While glass fibers show better impact behavior than carbon fibers at impact energies between 1.9 and 2.7 J, this is due to the large amount of epoxy resin in the case of glass fiber composite laminates, while the impact behavior is different at impact energies between 2.7 and 3.4 J. The fracture toughness K_IC is measured to be 192 and 31 MPa √m and the surface energy G_IC is measured to be 540.6 and 31.1 kJ/m² for carbon and glass fiber-reinforced epoxy laminates, respectively.     

Compressive and Energy Absorption Properties of Pyramidal Lattice Structures by Various Preparation Methods

Metallic three-dimensional lattice structures exhibit many favorable mechanical properties including high specific strength, high mechanical efficiency and superior energy absorption capability, being prospective in a variety of engineering fields such as light aerospace and transportation structures as well as impact protection apparatus. In order to further compare the mechanical properties and better understand the energy absorption characteristics of metal lattice structures, enhanced pyramidal lattice structures of three strut materials was prepared by 3D printing combined with investment casting and direct metal additive manufacturing. The compressive behavior and energy absorption property are theoretically analyzed by finite element simulation and verified by experiments. It is shown that the manufacturing method of 3D printing combined with investment casting eliminates stress fluctuations in plateau stages. The relatively ideal structure is given by examination of stress–strain behavior of lattice structures with varied parameters. Moreover, the theoretical equation of compressive strength is established that can predicts equivalent modulus and absorbed energy of lattice structures.     

Additive Manufacturing of Smart Composite Structures Based on Flexinol Wires

3D printing of a composite structure with shape memory materials requires a special approach to the subject, at the stage of the design and printing process. This paper presents the design steps during the development of a 3D-printed composite structure with shape memory material. The connection points between the SMA fibers and the printer filament are developed in the MATLAB environment. Finite element method is used to simulate the shortening of the shape memory material under the influence of temperature and its effect on the printed polymer material is presented. In the MATLAB environment, evolutionary algorithms were used to determine the shape of the SMA fiber alignment. This work demonstrates the use of shape memory effect in 3D printed smart composite structures, where the component takes a predetermined shape. The structure obtained as a result of such printing changes with the heat generated by the current voltage, making it the desired fourth dimension.     

Influence of the Size of the Fiber Filler of Corn Stalks in the Polylactide Matrix Composite on the Mechanical and Thermomechanical Properties

This paper presents results of a study on the effect of filler size in the form of 15 wt% corn stalk (CS) fibers on the mechanical and thermomechanical properties of polylactide (PLA) matrix composites. In the test, polylactidic acid (PLA) is filled with four types of length of corn stalk fibers with a diameter of 1 mm, 1.6 mm, 2 mm and 4 mm. The composites were composed by single screw extrusion and then samples were prepared by injection molding. The mechanical properties of the composites were determined by static tensile test, static bending test and Charpy impact test while the thermo-mechanical properties were determined by dynamic mechanical thermal analysis (DMTA). The composite structures were also observed using X-ray microcomputed tomography and scanning electron microscopy. In the PLA/CS composites, as the filler fiber diameter increased, the degradation of mechanical properties relative to the matrix was observed including tensile strength (decrease 22.9–51.1%), bending strength (decrease 18.9–36.6%) and impact energy absorption (decrease 58.8–69.8%). On the basis of 3D images of the composite structures for the filler particles larger than 2 mm a weak dispersion with the filler was observed, which is reflected in a significant deterioration of the mechanical and thermomechanical properties of the composite. The best mechanical and thermomechanical properties were found in the composite with filler fiber of 1 mm diameter. Processing resulted in a more than 6-fold decrease in filler fiber length from 719 ± 190 µm, 893 ± 291 µm, 1073 ± 219 µm, and 1698 ± 636 µm for CS1, CS1.6, CS2, and CS4 fractions, respectively, to 104 ± 43 µm, 123 ± 60 µm, 173 ± 60 µm, and 227 ± 89 µm. The fabricated green composites with 1 to 2 mm corn stalk fiber filler are an alternative to traditional plastic based materials in some applications.     

Frost Resistance Investigation of Fiber-Doped Cementitious Composites

Fibers used as reinforcement can increase the mechanical characteristics of engineering cementitious composites (ECC), but their frost resistance has received less attention. The mechanical properties of various fiber cementitious materials under the dual factors of freeze-thaw action and fiber dose are yet to be determined. This study examines the performance change patterns of cementitious composites, which contain carbon fiber, glass fiber, and polyvinyl alcohol (PVA) fiber at 0%, 0.5%, and 1% volume admixture in freeze-thaw tests. Three fiber cement-based materials are selected to do the compression and bending testing, and ABAQUS finite element modeling is used to assess the performance of fiber cement-based composite materials. The microscopic observation results show that the dispersion of glass and PVA fibers is higher than that of carbon fibers. As a result, the mechanical characteristics of the fiber-doped cementitious composites increase dramatically after freeze-thaw with increasing dosage. The compression test results show the frost resistance of carbon fiber > PVA fiber > glass fiber. In addition, the bending test results show the frost resistance of carbon fiber > glass fiber > PVA fiber. The 3D surface plots of the strength changes are established to observe the mechanical property changes under the coupling effect of admixture and freeze-thaw times. ABAQUS modeling is used to predict the strength of the cementitious composites under various admixtures and freeze-thaw cycles. The bending strength numerical equation is presented, and the bending and compressive strengths of three different fiber-cement matrix materials are accurately predicted.     

Experimental Investigation on the Influence of Fiber Path Curvature on the Mechanical Properties of Composites

Automated fiber placement (AFP) has been widely used as an advanced manufacturing technology for large and complex composite parts and the trajectory planning of the laying path is the primary task of AFP technology. Proposed in this paper is an experimental study on the effect of several different path planning placements on the mechanical behavior of laminated materials. The prepreg selected for the experiment was high-strength toughened epoxy resin T300 carbon fiber prepreg UH3033-150. The composite laminates with variable angles were prepared by an eight-tow seven-axis linkage laying machine. After the curing process, the composite laminates were conducted by tensile and bending test separately. The test results show that there exists an optimal planning path among these for which the tensile strength of the laminated specimens decreases slightly by only 3.889%, while the bending strength increases greatly by 16.68%. It can be found that for the specific planning path placement, the bending strength of the composite laminates is significantly improved regardless of the little difference in tensile strength, which shows the importance of path planning and this may be used as a guideline for future AFP process.     

CMT Additive Manufacturing Parameters Defining Aluminium Alloy Object Geometry and Mechanical Properties

Additive manufacturing technologies based on metal melting use materials mainly in powder or wire form. This study focuses on developing a metal 3D printing process based on cold metal transfer (CMT) welding technology, in order to achieve enhanced productivity. Aluminium alloy test specimens have been fabricated using a special 3D printing technology. The probes were investigated to find correlation between the welding parameters and geometric quality. Geometric measurements and tensile strength experiments were performed to determine the appropriate welding parameters for reliable printing. The tensile strength of the product does not differ significantly from the raw material. Above 60 mm height, the wall thickness is relatively constant due to the thermal balance of the welding environment. The results suggest that there might be a connection between the welding parameters and the printing accuracy. It is demonstrated that the deviation of ideal geometry will be the smallest at the maximum reliable welding torch movement speed, while printing larger specimens. As a conclusion, it can be stated that CMT-based additive manufacturing can be a reliable, cost-effective and rapid 3D printing technology with enhanced productivity, but without significant decrease in mechanical stability.     

Mechanical Properties of Flax Tape-Reinforced Thermoset Composites

Three thermoset resin systems—bio-epoxy, epoxy, and polyester-with 30 v% flax fiber reinforcement have been studied to identify the optimal fiber–resin combination in a typical composite structure. Tensile, interface and interlaminar shear strength together with flexural and impact damage tolerance were compared in this study. The results revealed that mechanical and interfacial properties were not significantly affected by the different resin systems. Microscopy studies reveal that epoxy laminates predominantly fail by fibre linear breakage, polyester laminates by fiber pull-out, and bio-epoxy laminates by a combination of the two. The higher failure strains and pull-out mechanism may explain the better impact damage tolerance of polyester composites. Flow experiments were also conducted, revealing faster impregnation and lower void content with polyester resin, followed by bio-epoxy, due to their lower viscosities. Overall, bio-epoxy resin demonstrates comparable performance to epoxy and polyester resins for use in (semi-)structural bio-composites.