3D printed continuous fiber-reinforced composites with high fiber bundle shape uniformity, mechanical performance consistency, and fiber content

IF 6.5 2区材料科学 Q1 MATERIALS SCIENCE, COMPOSITES

Composites Communications Pub Date : 2025-06-11 DOI:10.1016/j.coco.2025.102499

Jiangyang Xiang , Hao Lin , Depeng Wang , Yanni Rao , J.P.M. Correia , Said Ahzi , Yong Peng , Kui Wang

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引用次数: 0

Abstract

This study proposed a novel slot-assisted impregnation process to enhance the consistency of fiber bundle shape, improve the stability of the mechanical properties and achieve the manufacturing of 3D printed continuous fiber reinforced composites (CFRCs) with high fiber content. Kevlar fiber impregnated with PLA was used to fabricate CFRCs via in-situ and slot-assisted impregnation processes. Fiber bundle shape uniformity for CFRCs was analyzed. Tensile strength and its variability for CFRCs were assessed through quasi-static tension tests and a two-parameter Weibull analysis. The results showed that 3D printed CFRCs by slot-assisted impregnation method showed better shape uniformity of fiber bundles, with a narrower range of width and thickness distribution, resulting in higher tensile strength and consistency in mechanical properties. Moreover, only slot-assisted impregnation process could manufacture CFRCs with a fiber content of up to 40 vol%, while maintaining good fiber bundle shape uniformity. 3D printed CFRCs with high fiber content could exhibit better mechanical performance and functionality, making them more aligned with the standards of practical engineering applications.

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3D打印连续纤维增强复合材料，具有高纤维束形状均匀性，机械性能一致性和纤维含量

为了增强纤维束形状的一致性，提高纤维束力学性能的稳定性，实现3D打印高纤维含量连续纤维增强复合材料（CFRCs）的制造，本研究提出了一种新型的槽辅助浸渍工艺。用凯夫拉纤维浸渍PLA，通过原位浸渍和槽辅助浸渍法制备CFRCs。对碳纤维纤维束形状均匀性进行了分析。通过准静态拉伸试验和双参数威布尔分析评估CFRCs的抗拉强度及其变异性。结果表明：采用槽辅助浸渍法3D打印CFRCs，纤维束形状均匀性更好，纤维束宽度和厚度分布范围更窄，抗拉强度更高，力学性能一致性更好；而且，只有槽辅助浸渍工艺才能制备出纤维含量高达40 vol%的CFRCs，同时保持良好的纤维束形状均匀性。高纤维含量的3D打印CFRCs可以表现出更好的机械性能和功能，使其更符合实际工程应用标准。

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来源期刊

Composites Communications Materials Science-Ceramics and Composites

CiteScore

12.10

自引率

10.00%

发文量

340

审稿时长

36 days

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.