Integrating additively manufactured continuous glass fibre inserts in compression moulding: A novel approach to mitigating fibre–matrix separation effect

IF 8.2 2区材料科学 Q1 ENGINEERING, MANUFACTURING

Composites Part A: Applied Science and Manufacturing Pub Date : 2026-03-01 Epub Date: 2025-12-08 DOI:10.1016/j.compositesa.2025.109497

Udane Olaziregi, Aritz Esnaola, Maider Baskaran, Jon Aurrekoetxea

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引用次数: 0

Abstract

This study presents a novel approach to mitigate fibre–matrix separation defects in compression-moulded thermoplastic composite components by integrating additively manufactured (3D-printed) continuous fibre-reinforced inserts into the stiffener ribs. The design of these inserts was guided by topology optimisation and refined to align with additive manufacturing principles. The feasibility of embedding 3D-printed inserts was demonstrated, yielding hybrid parts with consistent quality, accurate positioning, and a defect-free insert/moulded part interface. Mechanical testing under three-point bending revealed substantial performance gains: stiffness, strength, deflection, and energy absorption improved by factors of up to 1.5, 3.5, 1.4, and 12, respectively. A 45 % reduction in insert thickness further enhanced manufacturability and interfacial bonding, shifting the failure mode from interfacial delamination at the rib base to fibre rupture at the rib tip. Despite the reduced material volume, stiffness decreased by only ∼17 %, while strength remained stable and toughness improved significantly.

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在压缩成型中集成增材制造的连续玻璃纤维嵌套：一种减轻纤维基质分离效应的新方法

本研究提出了一种新方法，通过将增材制造（3d打印）连续纤维增强插入件集成到加强筋中，来减轻压缩成型热塑性复合材料部件中纤维基质分离缺陷。这些刀片的设计以拓扑优化为指导，并根据增材制造原理进行了改进。验证了嵌入3d打印刀片的可行性，从而获得了质量一致、定位准确、无缺陷的刀片/成型部件界面的混合部件。三点弯曲下的力学测试显示了显著的性能提升：刚度、强度、挠度和能量吸收分别提高了1.5、3.5、1.4和12倍。插入件厚度减少了45%，进一步增强了可制造性和界面粘合性，将失效模式从罗纹底部的界面分层转变为罗纹尖端的纤维断裂。尽管减少了材料体积，但刚度仅下降了约17%，而强度保持稳定，韧性显著提高。

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来源期刊

Composites Part A: Applied Science and Manufacturing 工程技术-材料科学：复合

CiteScore

15.20

自引率

5.70%

发文量

492

审稿时长

30 days

期刊介绍： Composites Part A: Applied Science and Manufacturing is a comprehensive journal that publishes original research papers, review articles, case studies, short communications, and letters covering various aspects of composite materials science and technology. This includes fibrous and particulate reinforcements in polymeric, metallic, and ceramic matrices, as well as 'natural' composites like wood and biological materials. The journal addresses topics such as properties, design, and manufacture of reinforcing fibers and particles, novel architectures and concepts, multifunctional composites, advancements in fabrication and processing, manufacturing science, process modeling, experimental mechanics, microstructural characterization, interfaces, prediction and measurement of mechanical, physical, and chemical behavior, and performance in service. Additionally, articles on economic and commercial aspects, design, and case studies are welcomed. All submissions undergo rigorous peer review to ensure they contribute significantly and innovatively, maintaining high standards for content and presentation. The editorial team aims to expedite the review process for prompt publication.