Exploring new material options for continuous reinforcement in structural continuous fiber 3D printing
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School of Engineering |
Master's thesis
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Authors
Date
2024-09-30
Department
Major/Subject
Additive Manufacturing for Full Flexibility
Mcode
Degree programme
Master's Programme in Manufacturing
Language
en
Pages
66
Series
Abstract
The rapid advancement of Continuous fiber 3D printing has positioned it as a key technology in producing high-performance, lightweight components for industries such as aerospace, automotive, and construction. However, the limited availability of suitable continuous fiber filament reinforcements constraints innovation and supply chain flexibility. This thesis aims to address these challenges by identifying new suppliers for continuous fiber-reinforcement while evaluating their suitability for SCF (Structural Continuous Fiber) 3D printing applications. Specifically, the research focuses on the testing and comparative analysis of Anisoprint's Composite Carbon Fiber (CCF) and Composite Basalt Fiber (CBF) against the current supplier's carbon fiber product. The primary testing objectives include analysing the Fiber Volume Fraction (FVF), and the fiber distribution of the new materials. Cross-sectional analysis using optical microscopy and scanning electron microscopy (SEM) was employed to assess fiber alignment, spacing, and clustering. The results indicate that Anisoprint's CCF performed on par with the cur-rent supplier's product in terms of FVF, and fiber distribution, making it a viable alternative for high-performance applications. The CBF material, while slightly lower in strength, offers significant sustainability advantages and is recommended for use in non-critical structural components. This thesis concludes with an insight into expanding material options for continuous fiber reinforcement in SCF 3D printing, providing a framework for future material sourcing, testing, and integration.Description
Supervisor
Partanen, JouniThesis advisor
Luthada, PravinKeywords
composite, additive manufacturing, continuous reinforcement, fiber volume fraction, continuous fiber reinforced polymer composite, carbon fiber