Manufacturing and characterization of continuous carbon fiber reinforced polyphenylene sulfide filaments via melt impregnation method

The utilization of continuous fiber‐reinforced thermoplastic composites (CFRTP) in additive manufacturing technology (AM) is envisioned to enable the production of high‐performance parts with enhanced mechanical properties. In the production of CFRTP filaments, ensuring proper impregnation plays a crucial role in improving the characteristics of the produced filament. Carbon fiber (CF) reinforced polyphenylene sulfide (PPS) composites find applications in secondary aerospace parts, automotive structural parts, and chemical process applications. Continuous CF‐reinforced PPS filaments enable the production of lightweight, high‐performance parts with mechanical strength, heat, and chemical resistance in AM. In the present study, continuous CF‐reinforced PPS filaments were produced using the melt impregnation method for use in fused deposition modeling technology. Filament diameter, geometrical evenness, and effective fiber impregnation are important criteria in filament production. An impregnation mold was designed and manufactured to provide impregnation. The influence of three different pin angles (56°, 70°, and 82°) on impregnation and mechanical properties has been investigated by developing an impregnation die for CFRTP filament production. Tensile testing, fiber content analysis, optical microscopy, and scanning electron microscope analysis were performed on the produced filaments. Furthermore, increasing the pin angle leads to an increase in both the spreading and impregnation of fibers.Highlights Impregnation die for effective wetting of fibers with polymer. Significance of pin angle in fiber spreading and wetting with polymer. Application of test standards for fiber content.