Development of Novel Advanced Polymer and Composites Convergent System – Additively Reinforced Thermoforming (ART)

Abstract

This paper presents the development of the patented Additively Reinforced Thermoforming (ART) system, a novel convergent manufacturing approach that integrates extrusion deposition Additive Manufacturing (AM) with thermoforming for producing structurally optimized composite parts with enhanced performance. Thermoforming, known for its economical fabrication of thermoplastic components, offers rapid cycle times and the capacity to utilize 3D-printed or other cost-effective mold systems. However, the process is also characterized by limitations such as restrictions on the complexity of mold geometries and variability in thickness, especially for deep drawn parts. The latter leads to regions of reduced strength, which become potential structural weak points. Consequently, support structures are often required to achieve geometrical stiffness and enhance the structural integrity of such products. To address these challenges, the ART process incorporates reinforcement components onto the polymer sheet, which remain fully retained during and after thermoforming, thereby enabling selective modification of material properties in the final product. The precision and reproducibility inherent in 3D printing renders it an ideal method for achieving the desired targeted reinforcement. Compared to standalone approach, the selected integrated gantry-based ART system can reduce the levelized cost per unit by approximately 5.6%, demonstrating the efficiency and cost benefits of the convergent system.