{"title":"Additive Preform Molding of continuous carbon fiber thermoset composites","authors":"Kaiyue Deng , Md Habib Ullah Khan , Kelvin Fu","doi":"10.1016/j.coco.2025.102408","DOIUrl":null,"url":null,"abstract":"<div><div>Continuous carbon fiber thermoset composites are renowned for their exceptional mechanical and thermal properties. However, fabricating complex 3D composites has historically presented challenges due to their structural complexity. This study presents the Additive Preform Molding (APM) strategy, a novel hybrid manufacturing method that integrates additive manufacturing with overmolding to produce high-performance composite structures. APM optimizes the alignment of continuous fibers based on load requirements and enhances structural integrity, starting with the creation of semi-cured preforms. These preforms are precisely shaped into specific configurations and subsequently overmolded with an infusion of short fiber-reinforced epoxy, thus enhancing their mechanical properties and facilitating the design of intricate geometries. The versatility of APM is represented through fabrication of various bracket designs. Mechanical testing reveals a tensile strength of 1109.3 MPa, a tensile modulus of 103.5 GPa, a flexural strength of 854.7 MPa and a flexural modulus of 96.6 GPa, confirming its substantial load-bearing capabilities for high-performance applications. This study demonstrates that APM is not only a viable alternative to traditional composite manufacturing methods but also an ideal solution for producing complex, high-strength 3D composite structures.</div></div>","PeriodicalId":10533,"journal":{"name":"Composites Communications","volume":"56 ","pages":"Article 102408"},"PeriodicalIF":6.5000,"publicationDate":"2025-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Composites Communications","FirstCategoryId":"88","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S2452213925001615","RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q1","JCRName":"MATERIALS SCIENCE, COMPOSITES","Score":null,"Total":0}
引用次数: 0
Abstract
Continuous carbon fiber thermoset composites are renowned for their exceptional mechanical and thermal properties. However, fabricating complex 3D composites has historically presented challenges due to their structural complexity. This study presents the Additive Preform Molding (APM) strategy, a novel hybrid manufacturing method that integrates additive manufacturing with overmolding to produce high-performance composite structures. APM optimizes the alignment of continuous fibers based on load requirements and enhances structural integrity, starting with the creation of semi-cured preforms. These preforms are precisely shaped into specific configurations and subsequently overmolded with an infusion of short fiber-reinforced epoxy, thus enhancing their mechanical properties and facilitating the design of intricate geometries. The versatility of APM is represented through fabrication of various bracket designs. Mechanical testing reveals a tensile strength of 1109.3 MPa, a tensile modulus of 103.5 GPa, a flexural strength of 854.7 MPa and a flexural modulus of 96.6 GPa, confirming its substantial load-bearing capabilities for high-performance applications. This study demonstrates that APM is not only a viable alternative to traditional composite manufacturing methods but also an ideal solution for producing complex, high-strength 3D composite structures.
期刊介绍:
Composites Communications (Compos. Commun.) is a peer-reviewed journal publishing short communications and letters on the latest advances in composites science and technology. With a rapid review and publication process, its goal is to disseminate new knowledge promptly within the composites community. The journal welcomes manuscripts presenting creative concepts and new findings in design, state-of-the-art approaches in processing, synthesis, characterization, and mechanics modeling. In addition to traditional fiber-/particulate-reinforced engineering composites, it encourages submissions on composites with exceptional physical, mechanical, and fracture properties, as well as those with unique functions and significant application potential. This includes biomimetic and bio-inspired composites for biomedical applications, functional nano-composites for thermal management and energy applications, and composites designed for extreme service environments.